SARATOGA
MAINTENANCE MANUAL
CARD 1 OF 3
~a
PA-32-301/301 T SARATOGA
Courtesy of Bomar Flying Service
www.bomar.biz
I
I
I
I
PIPER AIRCRAFT CORPORATION
[PART NUMBER 761 7211
1Al
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Thls PIPER AIRCRAFT Maintenance Manual is prepared in accordance with the GAMA (General
Ablation Manufacturers Association) format. This maintenance manual is divided into various Groups u hlch
enable a broad separation of contents (Chapters) within each group.
The various Chapters are broken down into major systems such as Electrical Power. Flight Controls.
Fuel. Landing Gear. etc. The System~Chaptersare arranged more or less alphabetically rather than by
precedence o r importance. All System~Chaptersare assigned a number, which becomes the first element of a
standardized numbering system. Thus the element "32" of the number series 32-00-00 refers to the
System Chapter on "Landing Gear." All information pertaining to the landing gear will be covered in t h ~ s
System Chapter.
The major System/Chapters are then broken down into Sub-SystemlSections. These sections are
identified by the second element of the standardized numbering system. The number "40"of the basic number
series 32-40-00 is for the "Wheels and Brakes" portion of the landing gear.
The individual units within a Sub-System Section may be identified by a third element of the
standardized numbering system. such as 32-40-01. This number could be assigned by the manufacturer to f i t
the co\erage requirements of the publication.
Example:
CHAPTER: SYSTEM
LAISDING GEAR
SUB-SYSTEMS
AKD BRAKES
\
INDIVIDUAL UNITS
NOSE WHEEL REMOVAL
This manual does not contain hardware callouts for installation. Hardware callouts are only indicated
where a special application is required. T o confirm the correct hardware used, refer to the PA-32-301 301T
'parts Catalog PI& 761 720, and F A R 43 for proper utilization.
Introduction
Page 1
Issued: January 2, 1980
-
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
AEROFICHE EXPLASATIOX A S D REVlSlOV STATL'S
The \qainle,~;lncc \lanual information incorporated in this set of Aerofiche cards has been arranged in
accordance nith thc general specifications of Aerofiche adopted by the General Aircraft Manufacturer'\
.Association. ( G 4X1.4).The information compiled in this Aerofiche Maintenance Manual will be kept current
by re\ isions distributed periodically. These revisions will supersede all pre\.ious revisions and u i l l be complete
.Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set.
Con\ ersion of Aerofiche alpha numeric code numbers:
First number is the Aerofiche card number.
Letter ir the hori7ontal line reference per card.
Second number is the vertical line reference per card.
Example: ZJ I6 = Aerofiche card number two of given set. Grid location J Ih.
T o aid in locating the \arious chapters and related senice information desired. the follo~iingis pro\ idcd:
I . A complete manual System Chapter Index Guide is for all fiche in this set.
2 . A complete list of Illustrations is for all fiche in this set following S>,stem Chapter Indel.
3. A complete list of Charts is for all fiche in this set following list of Illustrations.
4 . A complete list of paragraph titles and appropriate Grid location numbers is gi\en at the beginn~n;(11.
each Chapter relating to the information within that Chapter.
5. Identification of Revised Material:
Re\ ised text and illustrations are indicated by a black \,ertical line along the left-hand margin t ~ i
the frame. opposite revised. added or deleted material. Re\.ision lines indicate onl! current re\ ;,ion\
with changes and additions to or deletions of existing text and illu\tration,. Change, In
capitali7ation. spelling. punctuation. indexing. the physical location of the material or complete page
additions are not identified by re\.ision lines.
A reference and record of the material revised is included in each chapter's Tahle 01'
Contents EffectiL ity. The codes used in the effectkit? columns of each chapter are defined as iollo\\ \ .
TABLE O F C O S T E S T S EFFECTIVITY CODES
Original Issue:
None
Revision Identification. ( 1 R Month-Year)
First Revision:
Second Revision: Revision Identification. (2R Month-Year)
All subsequent revisions will follow with consecutive re\,ision numbers
such as 3R. 4R. etc.. along with the appropriate month-year.
Added Subject: Revision Identification. ( A Month-Year)
Deleted Subject: Revision Identification. ( D Month-Year)
Introduction
Page 2
Revised: August 11. 1983
-
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
6.
Revisions to Maintenance Manual 761 721 issued January 2, 1980 are a s
follows:
Effectivity
Publication Date
January 2, 1980
May 21. 1980
August 19, 1980
September 23, 1981
February 19, 1982
August 23, 1982
August l I , 1983
August 9, 1984
August 15, 1985
April 30, 1986
~ u i y30, 1986
September 20, 1986
May 12, 1987
Aerofiche Card Effectivity
I , 2 and
I . 2 and
1 , 2 and
I. 2and
I, 2 and
I , 2 and
1. 2 a n d
1, 2 a n d
3
3
3
3
3
3
3
3
3
1
1
1
1
The date on Aerofiche cards must not be earlier than the date noted for the respective card effectivity. Consult
the latest Aerofiche card in this series for current Aerofiche card effectivity.
This publication contains material revised as of August 15, 1985
(with four interim revisions effective April 30, 1986, July 30, 1986,
September 20. 1986 and March 16. 1987).
INTERIM CHANGE
Revisions appear in chapter 5 of card 1. There are no other changes
in this maintenance manual. Please discard your current card 1 and
replace it with this revised one. D O NOT DISCARD CARDS 2 or
3.
Introduction
Page 3
Interim Revision: March 16, 1987
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE M A N L A L
E\GI\E.
O\erhaul \lanual
.4t'CO LYCOMING - OVERH .4C'L \I\\.I A L
DIRECT DRIi'E ESGlVE - P \ 60291-A \ co Lycoming Di\ ision
H'illiarnsport. Pa. 1770 1
Parts Catalog =
AVCO LYCOMIVG - P S PC-I02
Abco Lycorning Di\ ision
Williarnsport. Pa. 17701
Operators Handbook = AVCO LYCOMIVG 10-540 and TIO-540
SERIES AIRCRAFT ESGISES - P V 60297-10
A \ r o Lycoming Di\.ision
Williamsport. Pa. 1770 1
PROPEL1 E R :
O\erhaul Instructions = HARTZELL COMPACT COSST.\\T SPEED
and FEATHERISG PROPELLER - P S 11'-D
Hartzell Propeller Inc.
Piqua. Ohio 45356
\1.4GVETOS:
I nqtallation. Operation
and Maintenance
l nst ruct ions =
D-2000 and D-2200 SERIES M.4G\ETO
IGSITIOS SYSTEM - P S L-928
Bendix Electrical Components Di~lslon
Sidne!.. S ~ York
H 13838
.41'TO FLIGHT:
CEVTURY 41 A C T 0 PILOT
EDO-41 RE Mitchell
P.O. Box 610
31ineral H'ells. Texas 76067
Introduction
Page - 4
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
PIPER PL'BLICATIOSS.
CO\I \ I C \ I C A T I O S S :
Rrmo\ al. Installation
and Maintenance
Instructions =
761 502 Autocontrol Ill B S e n ice Vanual
761 481 AutoFlite I 1 S e n ice Manual
753 771 Pitch Trim S e n i c e Manual
Radio S e n i c e and
Maintenance Manual = 761 7 13 Avionics Wiring Diagram Ser\ ice Manual
Vol. I and Vol. 11 ( 1979)
REPAIRS:
A.B.S. Thermoplastic
Landing Gear Wheel
and Strut Fairing
Repair Instructions = 761 708V A.B.S. Thermoplastic Landlng Gear
Wheel and Strut Fairing Repair lnstructlon Manual
PARTS C A T A L O G =
PA-32-30] 3OlT
761 720
PERIODIC I S S P E C T I O N
REPORT FORM =
230 1046
PA-32-301 3OIT
PROGRAMMED ISSPECTIOY M A S U A L =
761 747
PA-32-301 3OIT
l ntroduction
-
Page 5
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
C A M A S Y S T E M I C H A P T E R INDEX GUIDE
SYST
CHAP
SUB-SYST
SECTIOS
TITLE
AEROFlCHE
G R I D \O.
AIRWORTHINESS
TIME LIMITS MAlNT CHECKS
I A'O
DIMENSIONS AND AREAS
lBl l
L I F T I K G A N D SHORllVG
LEVELISG A N D WEIGHING
TOWING A K D TAXIING
PARKISG A N D MOORING
REQUIRED PLACARDS
SERVICISG
- LUBRICATIOK
S T A S D A R D PRACT
- AIRFRAME
1C15
1D
'
O
ENVIRONMENTAL SYSTEM
AUTOFLIGHT
COMMUSICATIONS
ELECTRICAL POWER
EQUIPMENT: FURKISHINGS
FLIGHT CONTROLS
FUEL
LASDING GEAR
LIGHTS
NAVIGATION & PITOT, S T A T I C
OXYGEN
1A7
Introduction
Page - 6
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-30 1/30 1T
MAINTENANCE MANUAL
GAMA SYSTEM/CHAPTER INDEX GLIDE (cont)
SYST
CHAP
SUB-SYST
SECTIOS
37
VACUUM
39
ELECTRICAL
TITLE
AEROFICHE
G R I D KO.
STRUCTURES
DOORS
STABILIZERS
WISDOWS
WlSGS
PROPELLERS
'I'
S T A S D A R D P R A C T I C E S - ENGIKES
21 15
POWER PLANT
21 18
ENGIKE FUEL SYSTEM
IGSITIOS
ESGINE IKDICATISG
EXHAUST
OIL SYSTEM
STARTING
TURBINES
CHARTS A N D WIRING DIAGRAMS
SPECIAL PURPOSE EQUIPMENT
Introduction
Page 7
Revised: August 9. 1984
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS
FIGURE S O
GRID \ O
SUBJECT
Three View of PA-32-301
Three View of PA-32-301T
Station Reference Lines (PA-32-30 1 )
Station Reference Lines (PA-32-30 IT)
Access Plates and Panels
Jacking
Lekeling Airplane
Weighing
Placards and Decals
Fuel Filter Bowl and Screen
Servicing Points
Main Gear Oleo Struts (Cut-Away View)
Lubrication Chart (Landing Gear. Main)
Lubrication Chart (Landing Gear, Nose)
Lubrication Chart (Control System)
Lubrication Chart (Air Conditioning Condenser)
Lubrication Chart (Cabin Door. Baggage ~ o o r
and Seat)
Lubrication Chart (Power Plant. Propeller and
Control Pivot Points)
Lubrication Chart (Back-Up Extender and Fuel Selector)
Torque Wrench Formula
Method of Installing Rod End Bearings
Cherrylock Rivet Removal
Hose Line Markings
Flareless-Tube Fittings
Maximum Distance Between Supports for Fluid Tubing
Cabin Heater. Defrosters and Fresh Air System
( PA-32-30 1)
Cabin Heater. Defroster and Fresh Air System
( PA-32-30 1 T)
Air Conditioning System lnstallation (Typical)
Service Valves
Test Gauge and Manifold Set
Manifold Set Operation
Leak Test Hookup
E\acuation Hookup
Charging Stand
Charging Hookup
Compressor and Fabricated Oil Dipstick
Compressor and Alternator Belt Installation
Magnetic Clutch
Condenser Air Scoop Installation
Expansion Valve
Components Installation
Air Conditioning Wiring Schematic (Early Models)
Air Conditioning Wiring Schematic (Later Models)
IE15
I E23
I F4
I F5
I F6
I F7
I F9
IF11
I FI?
I F17
IF18
l F2O
I F24
1GI
1G3
I G4
1G5
Introduction
Page - 8
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
LISTOF ILLUSTRATIONS (cont)
SUBJECT
GRID \ O
Emergency Locator Transmitter Schematic
(Narco)
E LT.Portable Folding Antenna (Narco)
ELT Using Fixed Aircraft Antenna (Sarco)
Avionics Master and Emergency Switch Circuit
Exploded View of Alternator - Prestolite
Lamp-Bank Load
Removal of Slip Ring End Bearing
Removal of Rectifier
Removal of Drive End Head
Remo\al of End Head Bearing
Testing Rotor for Ground
Testing Rotor for Shorts
Installation of Bearing
Installation of Rectifier
Terminal Assembly - Prestolite
Slip Ring End Bearing Assembly
Testing Alternator
Brush Installation
Internal Wiring Diagram
Alternator Exploded View - Ford
Rear View Terminal Identification
Stator Core and Windings
Rectifier Assembly
Internal Relationship of Alternator Components
Rectifier Ground and Positive Diode Test
Stator Ground and Negative Diode Test
Field Circuit Open or Ground Test
Alternator Housing Disassembly
Rear Housing Components
Front Housing Disassembly
Front Housing Components
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
Introduction
Page 9
Revised: August 1 1, 1983
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANL'AL
LIST O F ILLUSTRATIONS (cont)
SUBJECT
Diode Testing
Front Housing Assembl!
Rear Housing Bearing and Brush Assembly
l nstallation
Rear Housing Components
H ousing Assembly
Alternator Installation - Ford
Seat Back Lock
Rod End Installation Method
Control Column Assembl)
Aileron Controls
Aileron Rigging
Bellcrank Rigging Tool
Aileron Rigging Tool
Aileron Rudder Interconnect
Rudder Controls
Rudder Rigging Tool
Rudder Tratel Adjustments
Rudder Rigging
Clamping Rudder Pedals
Rudder Trim Control
Rudder Steering Pedal Assembly
Stabilator Controls
Stabilator Rigging
Stabilator Tra\ el Adjustments
Methods of Securing Trim Cables
Stabilator Trim Controls
H'rapp~ngTrim Barrels
Stabilator Rigging Tool
Manually Operated Flap System
Flap Step Adjustment
Electrically Operated Flap System
Flap Rigging Tool
Fuel System (PA-32-301)
Fuel System (PA-32-f01T)
Fuel Cell Installation
1 nstallation of Locking Fuel Cap
Fuel Filter
Fuel Gauge
Main Gear Oleo Strut Assembly
Main Gear Installation
Nose Gear Oleo Strut Assembly
G R I D YO
1113
i115
1115
1116
112.1
15 12
lJ 13
1.1 I6
1j20
1j20
1j21
1j23
1K2
IK1
IK1
I K1
I KJ
1k5
1 K'
I K9
IKI!
1k15
1k15
IKI'
I K2O
I K20
I K21
I K21
I L2
I LJ
2,422
2 423
2 B3
2Bl l
2812
2B16
2824
2c2
2C4
I nttoduction
Page 10
Revised: August 9, 1984
-
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANLAL
LIST OF ILLUSTRATIONS (cont)
FIGURE \O.
SUBJECT
Sose Gear lnstallation
Clamping Rudder Pedals in Neutral Position
Rudder Pedals at Seutral Angle
Main Wheel Assembly
Sose Wheel Assembly
Brake Assembly
Removal and lnstallation of Anchor Bolts
Brake Disc Minimum Thickness
Brake System lnstallation
Brake Master Cylinder ( H a n d . Parking Brake)
Toe Brake lnstallation
Brake Cylinder ( 10-30) (Toe Brake)
Brake Cylinder ( 17000) (Toe Brake)
Landing Gear Fairing lnstallation
Strobe Light Connections
Pitot-Static System lnstallation
Fixed Oxygen System lnstallation
Test Apparatus for Testing Oxygen S!fstem
Oxygen Tubing Installation
lnstallation of Sn.agelock Fittings
Oxygen Cylinder and Regulator Assembly
Oxygen System Recharge Valve lnstallation
Ox!,gen Pressure Gauge lnstallation
Oxygen lnstallation (Portable)
Skin Material and Thickness
Surface Scratches. Abrasions or Ground-in-Dirt
Deep Scratches. Shallow Sicks and Small Holes
Mixing of Epoxy Patching Compound
Welding Repair Method
Repairing of Cracks
Various Repairs
Repair of Stress Lines
Repair of Impacted Damage
Snubber lnstallation
Empennage Group
Stabilator Balancing
Rudder Balancing
Windshield Installation (Typical)
GRID SO
2C8
2c10
2C lo
2Cl l
2C I?
2C15
2C16
2C16
2c11
2C18
2C20
2C2 1
2C2 1
'Dl
'Dl?
2d20
2et1
'El l
2E 13
SE 16
2E 19
2E 19
2e21
2F2
zf21
2G I
SG'
2G 2
2G3
2G3
2G 4
2G6
2G 6
2G I4
2G 23
ZH I
2H3
2H8
Introduction
Page 11
Revised: August 1 1. 1983
-
PIPER AIRCRAFT
PA-32-301130 1T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
FIGURE S O .
SUBJECT
GRID \O.
Side Windou Installation. Single Pane (Typical)
Wing lnstallation
Aileron and Flap Installation
Aileron Balance Configuration
Typical Nicks and Removal Method
Propeller lnstallation (PA-32-301)
Three Blade Propeller lnstallation (PA-32-301)
Propeller Installation (PA-32-30 IT)
Three Blade Propeller lnstallation (PA-32-301 T)
Propeller Governor
Engine Installation (PA-32-30 1)
E ngine Mount lnstallation (PA-32-301T)(Dynafocal)
Engine Mount Installation (PA-32-30 1 T) (Lord Mounts)
Fuel injector
Schematic Diagram of RSA Fuel Injection System
Fuel-Air Bleed Sozzle
Adjustment of Engine Controls
Height of Spring in Distributor Block Tower
Contact Points
Engine Timing Marks
Timing Light Connected to Magneto
Timing Marks on Magneto Rotor
Painted Tooth Centered in Timing Window
Timing Mark on Rotor Aligned with Pointer
Timing Light Connected to Magento and Breakers
Cam End View of Magneto
Removing Impulse Coupling
Checking Flyweight to Stop Pin Clearance
Stop Pin lnstallation Dimension
Checking Flyweight Axial Wear with Drill Shank
Checking Flyweight Radial Wear with Gauge
Points of Coupling Body Wear
Acceptable and Deformed Coupling Springs
Checking impulse Coupling for Magnetization
Orientation of Spring in Coupling Body
Lifting Inner End of Spring
Checking Harness Lead Continuity
Checking Harness Lead Insulation Resistance
Modified Pliers
Removing Spring From Lead Assembly
Assembly Tool
Using Assembly Tool
Ferrule Postioned Under Braid
Ferrule Seating Tool
Position of 11-8627 Kit and Contact Spring at
Start of lnstallation
Introduction
Page 12
Revised: August 1 1, 1983
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
LIST OF ILLCSTRATIONS (cont)
FIGURE K O .
SUBJECT
GRID 5 0
Position of 11-8627 Kit and Contact Spring
After Installation
Lubricating Sleeve
Lubricating Ferrule Shoulder
Removing Spark Plug Frozen to Bushing
Ignition Switch Wire Positions
Exhaust System Inspection Points
Exploded View of Gear Reduction Starting Motor
Turning Starting Motor Commutator
Testing Motor Armature for Shorts
Testing Motor Fields for Grounds
So-Load Test Hook-Up
Stall-Torque Hook-Up
Turbocharger Installation
Tire Balancer Fixture
Orifice Replacement Tool
Fabricated Tool for Baggage Door Lock
Retainer Ring Tool
Fabricated Aileron Bellcrank Rigging Tool
Fabricated Rudder Rigging Tool
Fabricated Aileron and Flap Rigging Tool
Fabricated Stabilator Rigging Tool
Control Surface Balancing Tool
Refer to Card 3, Grid No. 3011 for Electrical Schemaric Index.
lntroduct ion
Page 13
Revised: August 9. 1984
-
PIPER AIRCRAFT
PA-32-30] /301T
MAINTENANCE MANUAL
LIST OF CHARTS
SUBJECT
GRID SO.
Leading Particulars and Principal Dimensions
Thread Lubricants
Type of Lubricants
Hose Clamp Tightening (Initial Installation)
Blower System Wire Color Codes
Troubleshooting (Air Conditioner)
Troubleshooting (Air Conditioning System)
Temperature Pressure
Aluminum Tubing Torque
System Vacuum Chart
Compressor Oil Charge
Troubleshooting (Alternator)
Troubleshooting (Battery)
Alternator Specifications (Prestolite)
Alternator Belt Tension (Prestolite)
Hydrometer Reading and Battery Charge Percent
Electrical System Component Loads
Troubleshooting (Surface Controls)
Cable Tension Vs. Ambient Temperature
Troubleshooting Chart (Fuel System)
Fuel Cell Repair Equipment Lists
Sender, Fuel Quantity Gauge Tolerances
Troubleshooting Chart (Landing Gear)
Sose Gear Alignment Tolerances
Electrical System Troubleshooting
Troubleshooting (Rate of Climb Indicator)
Troubleshooting (Altimeter)
Troubleshooting (Airspeed Tubes and Indicator)
Troubleshooting (Gyro Horizon Indicator)
Troubleshooting (Directional Gyro Indicator)
Troubleshooting (Magnetic Compass)
Troubleshooting (Turn and Bank Indicator)
Troubleshooting (Oxygen System)
Oxygen System Component Limits (Fixed)
Filling Pressures for Certain Ambient Temperatures
Oxygen System Component Limits (Portable)
Troubleshooting (Vacuum System)
List of Materials (Thermoplastic Repair)
Propeller Specifications (PA-32-301)
Propeller Specifications (PA-32-301T)
Engine Troubleshooting Chart
Troubleshooting (Magneto)
Coupling Torques
introduction
Page 14
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
LIST O F CHARTS (cont)
CHART YO.
SUBJECT
GRID \ O
Troubleshooting (Manifold Pressure Indicator)
Troubleshooting (Tachometer)
Troubleshooting (Engine Oil Pressure Gauge)
Troubleshooting (Oil Temperature Indicators)
Troubleshooting (Exhaust Gas Temperature
Gauge) (Alcor)
Troubleshooting (Cylinder Head Temperature Gauge)
Troubleshooting (Starter)
Starting Motor Specifications
Troubleshooting (Turbocharger)
Tube and Hose Assembly Torque
Recommended Nut Torques
Decimal Conversions
Conversion Charts
List of Consumable Materials
Electrical Wire Coding
Electrical Symbols
Introduction
Page I S
Revised: August 9, 1984
-
CHAPTER
AIRWORTHINESS
LIMITATIONS
PIPER AIRCRAFT
PA-32-301 /3@I T
MAINTENANCE MANUAL
CHAPTER
SECTIOL
S t BJECT
4-00-00
4-0 1-00
SL BJECT
GRID
10.
EFFECTIi IT)
.AlR\I'ORTHISESS LIM ITATIO\S
General
- Cont./Effec.
-1
!
Revised: August 11. 1983
iI
4
Page
PIPER AIRCRAFT
PA-32-301 /301T
SIAINTENANCE MANUAL
T h e airworthiness limitations are F A A approved and specif!. inspections and maintenance req~ilrcd
under Part 91.163 of the Federal A\iation Regulations.
The following limitationsrelated t o fatigue life of the airplane and its components h a l e been c\tahl~.hr.J
with respect t o the PA-32-301 3OIT airplane:
I . T h e safe life of the airframe structure will be released when the information become\ a\allahle
2. T h e safe life limit of the propeller blades is unlimited.
Rejer to the LIMITATIONS in the Pilot's Operating Handbook
and FAA Approved Airplane Flight Manual for a detailed
delineation of the flight limitations ofthe airplane. The mandatory
replacement time and or inspection intervals of life Iimitedparts are
contained in Chapter 5 of this manual.
- END -
4-0 1-00
Page 4-01
Revised: August 11. 1982
CHAPTER
TIME LIMITS/MAlNT CHECKS
PIPER AIRCRAFT
PA-32-301 /301T
MAIlVTENANCE MANUAL
-
CH.4PTER 5 - TIME LIMITS/MAINTESASCE CHECKS
TABLE O F COSTEYTS/EFFECTII'ITY
CH.4PTER
SECTIOK
SI'BJECT
GRID
SUBJECT
50.
EFFECTI\'IT\t
TIME LIMITS
lnspection Requirements
Preflight Checks
O\erlimits lnspection
SCHEDULED MAIYTENASCE
Periodic Inspections
Programmed lnspection
1.423
I A23
l BlO
\:\SCHEDULED MAIYTEVASCE CHECKS
Spec~alInspections as Required. Upon Condit~on
l BlO
l BlO
3R h - $ 4
-
5 Cont./Effec.
Page 1
Revised: August 9. 1981
-
1
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
This chapter p r o ~ i d e sinstructions for conducting inspections. Repair or replacement instructions for
those components found to be unserviceable at inspection may be found in the chapters c o ~ e r i n gthe
applicable aircraft system. U hen working on engines. ground the magneto primary circuit before performing
an? operation.
TIME LIMITS.
INSPECTION REQUIREMENTS.
The required inspection procedures are listed in Periodic Inspections. T h e inspection procedure is broken
down into major groups which include Propeller. Engine. Turbocharger. Cabin. Fuselage and Empennage.
Wing. Landing Gear. Operational Inspection and General. T h e first column in each group lists the inspection
o r procedure to be performed. T h e second column is divided into four columns indicating the required
inspection i n t e r ~ a l sof 50 hours. 100 hours. 500 hours. and 1000 hours. Each inspection or operation 1 5
required a t each of the inspection intenals as indicated by a circle ( 0 ) . If a n item is not entirel! accessible or
.
to the applicable chapter of this manual for instructions on h o to
~ gain access to
must be r e m o ~ e d refer
remoLe the item. b hen performing inspections, use inspection forms furnished by the Piper Factory S e n Ice
Department. a t ailable through Piper Dealers o r Distributors.
- NOTE In addition to inspection intervals required in Periodic Inspections,
preflight inspections must be performed.
PREFLIGHT CHECKS.
This check is for the pilot and ' o r mechanic and should become part of the airplane operational routine
a n d or preflight check before each flight. Refer to Section 1V of the Pilot's Operating Manual for a I~stingof
items that must be checked.
OVERLI3IITS INSPECTION.
If the airplane has been operated so that any of its components have exceeded their maximum operational
limits. check uith the appropriate manufacturer.
5-1 3-00
Page 5-01
Revised: August 1 I , 1983
PIPER AIRCRAFT
PA-32-301/301 T
*MAINTENANCE MANUAL
,
SCHEDULED MAINTENANCE CHECKS.
PERIODIC INSPECTIONS.
Perjorm all inspections or operations at each inspection interval as
indicated by a circle (0).
(See Notes 1, 2, 3 and 4.)
Inspection Time (hrs)
Nature of Inspection
A . PROPELLER GROUP
I . Inspect spinner and back plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. lnspect blades for nicks and cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Check for grease and oil leaks.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Lubricate propeller per lubrication chart in maintenance manual. . . . . . . . .
5. Inspect spinner mounting brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. lnspect propeller mounting bolts and safety (check torque if safet!
is broken) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Inspect hub parts for cracks and corrosion.. . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Rotate blades and check for tightness in hub pilot t u b e . . . . . . . . . . . . . . . . .
9. Remove propeller: remove sludge from propeller and crankshaft . . . . . . . . .
10. lnspect complete propeller and spinner assembly for security, chafing.
cracks, deterioration, wear. and correct installation . . . . . . . . . . . . . . . . . . . .
I I. Overhaul propeller (per latest revision Hanzell Service
Letter 61) .........................................................
B. ENGINE CROUP
WARNING: Ground magneto primary circuit before working on
engine.
Read notes 5 . 23, and 24 prior to completing this inspection
NOTE:
group.
I . Remove engine cowl and inspect for damage ..........................
2. Clean and inspect cowling for cracks, distortion. and loose or
missing fasteners ..................................................
3. Drain oil sump (see note 6) .........................................
4. Clean suction oil strainer a t oil change (inspect for foreign
panicles) .........................................................
5. Change full flow (cartridge type) oil filter element (Inspect
element for foreign panicles) ........................................
5-21 -00
Pone 5-02
Interim Revision: September 26, 1986
PIPER AIRCRAFT
PA-32-301 1301 T
*MAINTENANCE MANUAL
--
PERIODIC INSPECTIONS. (cont)
Perform all inspections or operations at each of the inspection
{See Notes 1, 2, 3 and 4.1
intervals as indicated by a circk (0).
Nature of Inspection
. Inspection Time (hrs)
50
100
500
1000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
B. ESCINE CROUP (cont)
6. Inspect oil temperature sender unit for leaks and security ...............
7. Inspect oil lines and fitting for leaks, security, chafing, dents and
cracks (See Sote 8 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8. Clean and inspect oil radiator cooling fins.. ...........................
9. Remove and flush oil radiator (See Note 16) . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Fill engine with oil per information on cowl or lubrication chart
in Maintenance Manual ............................................ 0
11. Clean engine ......................................................
CAUTIOS: Use caution not to contaminate vacuum pump with
cleaning fluid. (Refer to latest revision Lycoming
1
1
Service Letter No. 1221)
I 12. lnspect condition of spark plugs (Clean and adjust gap as
1 required; adjust per latest revision Lycoming Service
/
Instruction S o . 1042). ..............................................
If fouling of spark plugs has been apparent, rotate
I! SOTE:
bottom plugs to upper plugs.
i 13. lnspect spark plug cable leads and ceramics for corrosion
I
and deposits ...................................................... 0
. 14. Check cylinder compression (Ref: AC 43.13-lA) . . . . . . . . . . . . . . . . . . . . . . .
: 15. Inspect cylinders for cracked or broken fins . . . . . . . . . . . . . . . . . . . . . . . . . . .
i 16. lnspect rocker box covers for evidence of oil leaks. If found.
1
replace gasket; torque cover screws 50 inch-pounds
i
1
(SeeNote12) ...................................................... 0
j NOTE:
Lycoming requires a Valve Inspection be made after
every 400 hours of operation. (See Note I I )
; 17. lnspect ignition harness and insulators for high tension leakage
andcontinuity .....................................................
18. Check magneto points for proper clearance (Maintain clearance
at.016) ...........................................................
. 19. Inspect magneto for oil seal leakage ..................................
1 20. Inspect breaker felts for proper lubrication ............................
21. lnspect distributor block for cracks, burned areas or corrosion.
and height of contact springs ........................................
22. Inspect magnetos to engine timing ...................................
23. Overhaul or replace magnetos (See Note 7). ...........................
24. Remove air filter and clean per Chapter 12 (Replace as
required) .......................................................... 0
,
0
0
5-21 -00
Page 5-03
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
PERIODIC INSPECTIONS. (cont)
Perform all inspections or operations at each of the inspection
intervals as indicated by a circle ( 0 ) . (See Notes 1, 2, 3 and 4.)
Inspection Time (hrs)
Nature of Inspection
50
100
500
1000
0
0
0
0
0
0
0
0
0
0
0
1 0
B. ENGINE GROUP (cont)
25. Clean fuel injector inlet line screen (Clean injector nozzles
as required) (Clean with acetone only) .... ; ...........................
26. Inspect condition of alternate air valve and housing
(Refer t o Note 13) .................................................
27. Inspect intake seals for leaks and clamps for tightness
(Torque clamps 40-50 inch-pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28. Inspect all air inlet duct hoses (Replace as required) . . . . . . . . . . . . . . . . . . . .
29. Inspect condition of flexible fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
30. Replace flexible fuel lines (See Note 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31. Inspect fuel system for leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32. Inspect fuel pumps for operation (engine driven and electric) . . . . . . . . . . . .
33. Overhaul or replace fuel pumps (engine driven) (See Note 7 ) . . . . . . . . . . . . .I
34. Inspect and replace electric fuel pump on condition . . . . . . . . . . . . . . . . . . . .
35. Inspect vacuum pump and lines.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36. Overhaul or replace vacuum pump (See Note 7) . . . . . . . . . . . . . . . . . . . . . . .
37. Inspect throttle. alternate air, mixture and propeller governor
controls for security.'trat.el and operating condition . . . . . . . . . . . . . . . . . . . .
38. Inspect exhaust stacks. connections and gaskets (Refer
to Chapter 78) (Replace gaskets as required). . . . . . . . . . . . . . . . . . . . . . . . . . .
39. Inspect muffler. heat exchange and baffles (Refer to Chapter 78) .........
40. Inspect breather tube for obstructions and security .....................
41. Inspect crankcase for cracks. leaks. and security of seam bolts ............
42. Inspect enpne mounts for cracks and loose mounting.. .................
43. lnspect all engine baffles (also check engine baffle seals on
PA-32-301T) ......................................................I
44. lnspect rubber engine mount bushings for deterioration
(Replace as required) ...............................................
45. Inspect fire wall seals.. .............................................
46. Inspect condition and tension of alternator drive belt (Refer to
Chapter 24 or Chapter 21 if air conditioning is installed). ...............
47. Lubricate alternator idler pulley (if installed); remove front grease
seal and add grease (Refer to lubrication chart Chapter 12). .............
I
I 1i :
1 1
i
0
I
0
0
0
0
0 1 0
1
0
;
O
o i o
!
0 1 0
0
1
I
!
I
1 0
i
0 1 0
jo
9 1
l' o0
0 1 °
O
0
O i O
1 11;
0
0
0 1 0
0
0
5-21-00
Page 5-04
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
'MAINTENANCE M A N U A L
PERIODIC INSPECTIONS. (cont)
-NOTE
-
Perjonn a11 inspections or operations at each o/ the inspection
intervals as indicated by a cbcle (0).(See Notes 1, 2, 3 and 4,)
Inspection Time (hrs)
Nature of Inspection
B. ENGINE GROUP (cont)
. ..... . . ... . . . .. . . . . . . . . . . .
. . . . . . .... . . . . . . . . . . . . .
... .. ...
.. .
..
. . . . .. .. . . . . . . .
.
.... . .. . . . .
. . .. . . . . .
. . . . .. . . . . . . . . . . . . . . .
..
48. Inspect condition of alternator and starter..
Inspect security of alternator mounting
..
. . .. . .
Check air conditioning compressor oil level (See Note 9 ) . .
. . ....
Inspect condition of compressor belt and tension (See Chapter 21)
... .
Inspect compressor clutch security and wiring (See Note 10). . . . . . . . . . .
Inspect security of compressor mounting
.
. . . . . .. . . . . ..
/
Check fluid in brake reservoir (Fill as required). . .
. .. .. . . ...
i
Inspect and lubricate all controls (Refer to Chapter 12) .
...
. ...
Overhaul or replace propeller governor (Refer to latest revision
i
of Hartzell Service Letter No. 61)
.
..
. . . . . . . .. .
i 57. Complete overhaul of engine or replace with factory rebuilt
(See Note 7) .......................................................
58. Reinstall engine cowl . . . . . . . . .
. . . . . . . . . . . . . . . . .. .
1
:
49.
50.
51.
52.
53.
54.
55.
56.
..
. . . . . . . .. . .. . . . .
C. TURBOCHARGER GROUP (PA-32-301T)
.. ... . . . ...
I
I
1. Visually inspect system for oil leaks, exhaust system leaks
and general condition
. .. .
..
..
. .. . . . . .
2. Inspect the turbo housing for cracks.. . . .
. . . . .. . . . . . . . .
3. Inspect the compressor wheel for nicks, cracks or broken blades . . . .
4. Inspect for excess bearing drag or wheel rubbing against housing..
...
5. Inspect turbine wheel for broken blades or signs of rubbing
...
6. Inspect turbocharger to tailpipe coupling clamp for
proper seating and nut torque of 40-50 inch pounds and bypass
coupling clamp for proper seating and nut torque to 80-90 inch pounds.
Safety the clamp nuts. Refer to Maintenance Manual "Installation of
Turbocharger.". .. .
..
.....
.. ...
7. Inspect the wastegate for freedom of operation
. .
.. .
8. Inspect operation of alternate air control..
.. .
9. Inspect oil inlet and outlet pons in center housing to include the
inlet check valve for leaks.. .
.
10. Inspect turbine heat blanket for condition and security..
.. .
11. Inspect interconnect linkage between wastegate valve and throttle
12. Inspect induction and exhaust components for worn or
damaged areas, loose clamps, cracks and leaks..
13. Inspect fuel injection nozzle reference manifold for deteriorated
hose, loose connections, leaks or obstructions..
14. Inspect operation of compressor bypass door
. .
15. Reinstall engine cowl . .
.
.
. . . . . ... .
I
.
. . ... . . .. . . . . .. . . . . . .
. . . .. .. . . . .
. .. .
. . . ..
.. . .
.... .. . . . .
. . ..... ........... ... . .. .
. .. . . .. . ... ... . . . . .
........ ...... .. . .. ... . . .
. ............. ..... . ... . .... . . . . . . . . . . .
.... . . . . . . . . .
.. . . . .. .
... ................ ....
. . ......... ... ... . .. . . ..
.............. . . .. . . ....
. . . .. . .. ............. ..... ........ . . .. . ....
0
0
0
0
0
5-11-00
Page 5-05
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301 T
'MAINTENANCE M A N U A L
PERIODIC INSPECTIONS. (cont)
Perform all inspections or operations at each of the inspection
intervals as indicated by a cucle (0).
(See .Notes 1, 2, 3 and 4.)
In3pection Time ( h r \ )
Nature of Inspection
50
I00
500
I000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
D. CABIN CROVP
.
I . lnspect cabin entrance. doors and uindows for damage.
operation and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Inspect upholstery for tears . . . . :. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 . Inspect seats. seat belts. security brackets and b o l t s . . . . . . . . . . . . . . . . . . . . .
4. Inspect trim operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Inspect rudder pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . In$pect parking brake t a l t e and brake handle for operation
and c!.linder leaks.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. In\pect control u heels. column. pulleys and cables (See S o t e 18) . . . . . . . . .
8. Inspect flap control cable attachment bolt (Manually operated flaps only) .
9 . O n aircraft S \ 32-H5---- and up. inspect the electric flap
sclecror handle cable attachment for an!. signs of cable f r a y i n g . . . . . . . . . . .
10. O n aircraft S V 12-85---- and up. inhpect the electric flap
\creu jack and attachments for condition and lubrication . . . . . . . . . . . . . . .
I I . Check landing. navigation. strobe. cabin and instrument lights . . . . . . . . . . . 0
12. lnspect instruments. lines and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I?. lnspect ro operated instruments and electric turn and bank
t o t e r h a u l o r replace as required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14. Rep1;ice central air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.'Cle;in or replace t a c u u m regulator filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16. In\pect altimeter (Calibrate altimeter system in accordance ~ i t h
F4R 91.170. if appropriate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17. Inqprct operation of fuel selector valte. (See h'ote 22) . . . . . . . . . . . . . . . . . .
I H. I n\pect fuel t alt e drain let er cot.er for security and door for
proper operation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
19. Inspect condition of heater controls a n d ducts . . . . . . . . . . . . . . . . . . . . . . . . .
20. Inspect condition and operation of air t e n t s . . . . . . . . . . . . . . . . . . . . . . . . . . .
21. Inspect condition of air conditioning ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. Rernotr ;ind clean air conditioning etaporator f i l t e r . . . . . . . . . . . . . . . . . . . .
0 ,
0 1
I
0
5-21-00
Page 5-06
Revised: August 9. 1984
I
I
PIPER AIRCRAFT
PA-32-301/301 T
'MAINTENANCE MANUAL
PERIODIC INSPECTIONS. (cont)
-
NOTE
-
Peuonn aU inspections or oprmtlons at each of the hptction
intervah as indicated by a circk (0). (See Notes 1, 2, 3 and 4.)
Inspection Time (hrs)
Nature of Inspection
100
500
1000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5 0
E. FUSELAGE AND EMPENNAGE CROUP
.......................... .....
1. Remove inspection plates and panels
..
2. Inspect baggage doors, latches and hinges for operation
and security
3, Inspect battery, box and cables (Inspect at least every 30 days.
Flush box as required and fill battery per instructions on box). . . . . ..
4. Inspect electronic installations
.. .
..
5. Inspect bulkheads and stringers for damage
.. .
. .. .
6. Inspect antenna mounts and electric wiring..
...
... .
7. Inspect air conditioning system for freon leaks..
..
. . ..
8. Inspect freon level in sight gauge of receiverdehydrator
.
.....
(Refer to Chapter 21).
9. Inspect air conditioner condenser air scoop rigging
. . ..
10. Inspect fuel lines, valves, and gauges for damage and operation
.. ....
11. Remove, drain, and clean fuel strainer bowl and screen located in
. ...
bottom of selector valve. (Drain and clean a t least every 90 days)
12. Inspect security of all lines
. ..
13. Inspect vertical fin and rudder surfaces for damage..
. .. . .
14. Inspect rudder hinges, sector and attachments for damage, security
.
..
.. . .
and operation .
15. Inspect vertical fin attachments for security..
. .. .
16. Inspect rudder control stops to insure stops have not
.
.. . .
loosened and locknuts are tight
17. Inspect rudder hinge bolts for excess wear (Replace as required)
.. . ...
18. Inspect stabilator surfaces for damage
.
... .
19. Inspect stabilator tab hinges, horn and attachments for damage,
security and operation..
... ... ..
. . .. . .
20. Inspect stabilator attachments for security and condition (see latest
. ..
Piper Service Bulletin 856)
21. Inspect stabilator and tab hinge bolts and bearings for excess wear
(Replace as required).
.
22. Inspect stabilator control stops to insure stops have not
....
loosened and locknuts are tight
23. Inspect stabilator trim mechanism..
. . ..
.
24. Check all cable tensions (use tensiometer) (See Note 17)
.
.. .
25. Inspect aileron, rudder, stabilator, stabilator trim cables, turnbuckles,
guides and pulleys for safety, damage and operation (See Note 19) ....
26. Clean and lubricate stabilator trim drum s c ~ w
(Refer to
Lubrication Chart)
..
27. Clean and lubricate all exterior needle bearings
. .
.......................................................
. . ..
.......................... .. . .. . ..
.............. ..... .
......... ........ ..
......... ....... .
....... ........................... ......
....... .... ......
.. . .
....
................................... . ...
........ ... ...
....... .............................. ........
................... ...
........................... ......
...
............... ........ ... .
............... .... ..... ......
..
.................................... ...
............................. ............. ...
............................... . . .
...................... . . .....
... .........
...
............................................ . ..
................. .... .
0
0
5-21-00
Page 5-07
Revised: A u ~ u s t11, 1983
Interim Revision: ~ l r c h16, 1987
PIPER AIRCRAFT
PA-32-301/301T
'MAINTENANCE MANUAL
•
PERIODIC INSPECTIONS. (cont)
Perform all inspections or operations at each of the inspection
intervah as indicated by a circle (0).(See Notes 1, 2, 3 and 4.)
lnspect~onTime (hrs)
Nature of Inspection
50
100
1000
500
E. FUSELAGE AND EMPENNAGE GROUP (cont)
,
I
''
1
28. Lubricate per lubrication chart (Refer to Chapter 12) ................... 0
29. Inspect anti-collision light for security and operation ...................
30. Inspect security of Autopilot bridle cable clamps
(Refer to Chapter 22). ..............................................
31. lnspect all control cables, aileronlrudder interconnect cables, air ducts.
electrical leads. lines, radio antenna leads and attaching parts for
security. routing. chafing, deterioration. wear and correct installation ....
32. Inspect emergency locator transmitter battery for replacement date
or time (See latest revision Piper Service Letter No. 820). ...............
33. Reinstall inspection plates and panels.. ...............................
! F.
I
WING GROLrP
1
0
0
0
0
0 ' 0
0
0
0
0
0
0
0
0
0
0
0
0
i
'1
I
0
j O ' 0
1. Remove inspection plates and fairings ................................
2. Inspect surfaces and tips for damage, loose rivets, and condition of
0
0
walkway ..........................................................
O
0
0
3. Inspect aileron hinges and attachments ...............................
I 4. Inspect aileron controls stops to insure stops have not
I
0 1 0
0
loosened and locknuts are tight ......................................
I
5. Inspect aileron cables, pulleys and bellcranks for damage and
0
0 1 0
i operation. Check stops for security (See Note 20) ......................
O
6. Inspect flaps and attachments for damage and operation ................
1
7. Inspect condition of bolts used with hinges (Replace as required). ........
O I 0
0
0
0
0
8. Lubricate per lubrication chart in Maintenance Manual.. ............... 0
0
0
0
I 9. Inspect wing attachment bolts and brackets ...........................
0
0
0
10. lnspect fuel tanks and lines for leaks and water (See Note 14) ...........
0
0
0
I I. Fuel tanks marked for capacity ...................................... 0
0
0
0
12. Fuel tanks marked for minimum octane rating.. .......................
0
13. lnspect fuel cell vents (See Note 15) ..................................
0 1 0
' 14. Inspect all control cables, air ducts, electrical leads, lines, and attaching
l
I
parts for security. routing, chafing, deterioration, wear and correct
o
installation ........................................................
15. Inspect security of Autopilot bridle cable clamps
o o o
(Refer to Chapter 22). ..............................................
0
0
0
16. Reinstall inspection plates and fairings.
1 0
1
i
,
!
I
a
I
...............................
1
OIO
5-11-00
Page 5 0 8
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
a
.
PERIODIC INSPECTIONS (cont)
Perform all inspections or operations at each of the inspection
intervals as indicated by a circle (0) (See Notes I . 2. 3 and 4.)
.
-
--
-
lnspection Time (hrs)
Nature of Inspection
50
.
100
500
1000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
C LANDING GEAR GROUP
I . Check oleo struts for proper extension (Check for proper
fluid level as required) .............................................. 0
2 . Inspect nose gear steering control and travel ...........................
3. Inspect wheel alignment ............................................
4 . Put airplane on jacks ...............................................
5 . Inspect tires for cuts . uneven or excessive wear and slippage .............
6 . Remove wheels . clean inspect and repack bearings .....................
7 . Inspect wheels for cracks corrosion and broken bolts ..................
8.Checktirepressure ................................................. 0
9 . Inspect brake lining and disc for wear ................................
10. Inspect brake backing plates for cracks ...............................
I I . Inspect condition of brake lines ......................................
I2 . Inspect shimmy dampener operation .................................
13. Inspect gear forks for damage .......................................
14. Inspect oleo struts for fluid leaks and scoring ..........................
I5 . lnspect gear struts . attachments torque links and bolts for
condition and security ..............................................
16. Lubricate per lubrication chart (Refer t o Chapter 12) ................... 0
17 . Remove airplane from jacks .........................................
.
.
.
.
.
H OPERATIONAL INSPECTION
...............................
2 . Check fuel quantity . pressure and flow readings ........................
3 . Check oil pressure and temperature ..................................
4 . Check alternator output ............................................
5 . Check manifold pressure ............................................
6 . Check alternate air .................................................
1 . Check fuel pump and fuel tank selector
0
0
0
0
0
0
5-2 1-00
Page 5-09
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-3011301T
'MAINTENANCE MANUAL
.
PERIODIC INSPECTIONS (cont)
Perjorm a11 inspections or operations at each oj the inspection
intervals as indicated by a circle ( 0 ). (See Notes 1. 2. 3 and 4.)
lnspection Time (hrs)
Nature of Inspection
H . OPERATIONAL INSPECTION (cont)
7 . Check parking brake ...............................................
8 . Check vacuum gauge ...............................................
9 . Check gyros for noise and roughness .................................
10. Check cabin heater operation ........................................
I I . Check magneto switch operation .....................................
12.CheckmagnetoRPMvariation ......................................
13. Check throttle and mixture operation .................................
14. Check propeller smoothness .........................................
15. Check propeller governor action .....................................
16. Check engine idle ..................................................
17. Check annunciator light panel .......................................
18. Check electronic equipment operation (Avionics master and
emergency switch . etc.) .............................................
19. Check air conditioner compressor clutch operation .....................
20 . Check air conditioner condenser scoop operation ......................
21 . Check operation of Autopilot and Automatic Trim (See Note 21) ........
I
.
-
50
100
500
1000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
O
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
GENERAL
I . Aircraft conforms t o FAA Specification ..............................
2 . All latest FAA Airworthiness Directives complied with .................
3. All latest Manufacturers Service Bulletins and Letters
complied with .....................................................
4 . Check for proper Pilot's Operating Handbook .........................
5 . Aircraft papers in proper order ......................................
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5-21-00
Page 5-10
Revised: August 11. 1983
.
PIPER AIRCRAFT
PA-32-301/3OlT
*MAINTENANCE MANUAL
PERIODIC INSPECTIONS (cont)
NOTES:
I . Refer to the last card of the Piper Parts Price List Aerofiche, for a check list of current revision dates
to Piper inspection reports and manuals.
2. All inspections or operations are required at each of the inspection intervals as indicated by a (0).
Both the annual and 100hour inspcctionsarecomplete inspections of the airplane, identical in scope.
while both the 500 and 1000 hour inspections are extensions of the annual or 100 hour inspection.
which require a more detailed examination of the airplane, and overhaul or replacement of some
major components. Inspections must be accomplished by persons authorized by the F A A .
3. Piper service bulletins are of special i m p o n a n a and Piper considers compliance mandatory.
4. Piper service letters are product improvements and service hints pertaining to servicing the airplane
and should be given careful attention.
5 . Inspections given for the power plant are based on the engine manufacturer's operator's manual
(Lycoming Pan No. 60297-10) for this airplane. Any changes issued to the engine manufacturer's
operator's manual shall supersede or supplement the inspections outlined in this report.
6. lntervals between oil changes can be increased as much as 100% on engines equipped with full flow
(cartridge type) oil filters. provided the element is replaced each 50 hours of operation.
7. Replace or overhaul as required or at engine overhaul. (For engine overhaul, refer to latest revision
Lycoming Service Letter L201.)
8. Replace flexible oil lines at engine TBO per latest revision Lycoming Service Bulletin 240.
9. The compressor oil level should not be checked unless a Freon leak has occurred, requiring an
addition of Freon to the system.
10. Clean any traces of oil from the clutch surface.
I I. At every 400 hours of engine operation, remove the rocker box covers and check for freedom of valve
rockers when valves are closed. Look for evidence of abnormal wear or broken parts in the area of
the valve tips, valve keeper, springs and spring seat. If any indications arc found, the cylinder and all
of its components should be removed (including the piston and connecting rod assembly) and
inspected for further damage. Replace any pans that do not conform with limits shown in the latest
revision for Lycoming Service Table of Limits SSP-1776.
12. Check cylinders for evidence of excessive heat indicated by burned paint on the cylinders. This
condition is indicative of internal damage to the cylinder and its cause must be determined and
corrected before the aircraft is returned to service.
Heavy discoloration and appearance of seepage at the cylinder head and barrel attachment area
is usually due to emission of thread lubricant used during assembly of the barrel at the factory, or by
slight gas leakage which stops after the cylinder has been in service for awhile. This condition is
neither harmful nor detrimental to engine performance and operation. If it can be proven that
leakage exceeds these conditions, the cylinder should be replaced.
I . Check throttle body attaching screws for tightness; the correct torque for these screws is 40 to 50
inch-pounds.
14. Replace flexible fuel supply hose and interconnect hose couplings at time of engine overhaul.
15. Replace fuel tank vent line flexible connections as required, but no later than 1000 hours of service.
-
5-21-00
Page 5-11
Interim Revision: September 20, 1986
PIPER AIRCRAFT
PA-32-301 / 301T
MAINTENANCE MANUAL
PERIODIC INSPECTIONS. (eont)
NOTES (eont):
16. Refer to latest revision Piper Service Bulletin 586, inspection and replacement of engine oil
coolers.
17. Maintain cable tensions specified in chapter 27.
18. Refer to latest revision Piper Service Bulletin 619.
19. Refer to latest revision Piper Service Bulletin 701.
20. Refer to latest revision Piper Service Bulletin 703.
21. Refer to index of vendor publications for appropriate manual p a n number.
22. Refer to and comply with latest Piper Service Bulletin 772.
23. Refer to Lycoming Service Bulletin 469.
24. Refer to VSP 69
100 Hour/Annud Inqection Report printed copies can be
obtained jrom Piper Service Sales under Piper Part Number 230
-
1046.
5-21-00
1B9
Page 5-12
Interim Revision: !September 20, 1986
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
PROGRAMMED INSPECTION.
The programmed inspection was designed to permit the best utilization of the aircraft, by scheduling
inspections through the use of a planned inspection schedule. This programmed inspection schedule is prepared in a manual form which is available from Piper Service Sales - order Piper Part No. 761-747.
UNSCHEDULED MAINTENANCE CHECKS.
SPECIAL INSPECTIONS A S REQUIRED, UPON CONDITION.
The special inspections given, supplement the scheduled inspections as outlined in Periodic Inspections,
to include inspections which are required at intervals not compatible with airframe operating time or
inspection intervals. Typical of this type are:
1. Inspections required because of special conditions o r incidents that arise, and because of these
conditions o r incidents, a n immediate inspection would be required to insure funher safe flight.
2. Hard or Overweight Landing. This inspection should be performed after a known rough landing is
made o r when a landing is made while the aircraft is known to exceed the design landing weight.
Check the following areas and items:
0 Wings - for wrinkled skins, loose or missing rivets.
Fuel leaks around the fuel tanks. and fuel fittings throughout the wings.
0 Wing spar webs, bulkheads. nacelle skins and attachments, wing and fuselage stringers and skins
for any signs of overstress or damage.
A possible alignment check to clarify any doubt of damage.
3. Severe Turbulence Inspection. The same items and locations should be checked as stated for Hard or
Overweight Landings along with the following:
0 Top and bottom fuselage skins for loose or missing rivets and wrinkled skins.
0 Empennage skins and attachments.
4. Engine overspeed, sudden stoppage. loss of oil, ovenemperature and lightning strike.
Refer t o Engine Manufacturer for necessary corrective action.
5. Component overlimits inspection.
0 Check with the appropriate manufacturer for the necessary corrective action.
-END -
5-51-00
Page 5- 13
Revised: August 11, 1983
a
CHAPTER
I
I
DIMENSIONS AND AREAS
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 6 DIMENSIONS A N D AREAS
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION
SUBJECT
SUBJECT
6-10-00
DIMENSIONS
6-20-00
STATION REFERENCE LINES
6-30-00
ACCESS AND INSPECTION PROVISIONS
6-40-00
WEIGHT AND BALANCE DATA
6-50-00
SERIAL NUMBER PLATE
GRID
NO.
EFFECTIVlTY
-
6 Cont./Effec.
Page 1
Revised: August 23, 1982
-
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
DIMENSIONS.
The principal airplane dimensions are shown in Figures 6-1 and 6-2 and are listed in Chart 601.
CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMEKSIOSS
PA-32-30 I
PA-32-30 I T
Manufacturer
Model
Rated Horsepower and Speed
Avco-Lycoming
10-540-K I G5D
300 hp @ 2700 rpm
Oil Sump Capacity
Fuel, Aviation Grade (Minimum
and Specified Octane)
Fuel Injector. Bendix
I2 U.S. quans
Avco-Lycorning
T10-540-S I AD
Take-off power
(5 minutes
max.) 300 hp
at 2700 rprn
at 36 in. h e .
max. Cont~nuous
power 270 hp
at 2575 rprn at
33 In. hg
12 U.S. quarts
MODEL
ENGINE
Magnetos, Bendix
Magneto Timing
Magneto Point Clearance
Spark Plugs
Spark Plug Gap Setting
Firing Order
Starter. Prestolite I2 volt
Alternator:
Prestolite. 12 volt. 60 amp
Ford, I2 volt. 90 amp
Voltage Regulator, WlCO
Overvoltage Relay, WlCO
Fuel Pump
I
100: 130
RSA-IOEDI or RSA-IOED2
100' 130
RSA-IOEDI or
RSA-IOED2
D6LN-203 1 (Dual
D6LN-203 I (Dual
Mag with impulse
Mag with ~mpulse
coupling)
coupling)
20 degrees BTC
20 degrees BTC
0.016 in.
0.016 in.
Refer to latest revision of Lycoming Service
Instruction No. 1042.
Refer to latest revision of Lycoming Service
Instruction No. 1042.
1-4-5-2-3-6
1-4-5-2-3-6
M24222
M24222
ALY 64211, ALY 6422'
X 16300B
X 16799
AC Pump Lycoming
P a n No. 75247
ALY 6421'. ALY 6422:
EOFF- 10300-AA'
X 16300B
X 16799
Lear-Siegler RG9080J6A
Without Alr C o n d l t ~ o n l n #
W ~ t hAir C o n d ~ t ~ o n l n g
O p t ~ o n a lEqu~pmcnto n PA-32-30lTOnly
*
6- 10-00
Page 6-01
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
CHART 601. LEADING PARTICULARS A N D PRINCIPAL DIMEKSIONS (cont)
MODEL
PA-32-30 I
PA-32-30 IT
Hanzell
Refer to Chart 6101
Refer to Chan 6101
Hanzell
F4-I I BZ
Hanzell
Refer to Chan 6102
Refer to Chan 6102
Hanzell
F4-I 1 BZ
4 (2 interconnected
4 ( 2 interconnected
each wing)
53.5 U.S. gallons
(each set)
2.5 U.S. gallons
(each set)
107 U.S. gallons
5 U.S. gallons
Airborne 1 B5-6
each w~ng)
53.5 U.S. gallons
(each set)
2.5 U.S. gallons
(each set)
107 U.S. gallons
5 U.S. gallons
Weldon 10080-B
PROPELLER
Manufacturer
Hub. Model
Blade. Model
Governor Control
Governor. Model
FUEL SYSTEM
Fuel Tanks
Capacity
Unusable Fuel
Total Capacity
Total Unusable Fuel
Electric Fuel Pump
6- 10-00
Page 6-02
Revised: May 21, 1980
PIPER AIRCRAFT
PA-32-301 1301T
'MAINTENANCE MANUAL
CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont)
r
MODEL
PA-32-30 1 i' 30 1 T
LANDING GEAR
TYpe
Shock Strut Type
Fluid Required (Struts and Brakes)
Strut Extension (Exposure under Static Load):
Nose
Main
Wheel Base
Nose Wheel Travel
Turning Distance (Min.)
Wheel. Nose
Wheel, Main
Brake Type
Tire. Nose
Tire, Main
Tire Pressure, Nose, Standard
Tire Pressure. Main. Standard
Tire Pressure, Nose, Heavy Duty, 5 inch
Tire Pressure. Main. Heavy Duty, 6 inch
(With 5 inch Nose Wheel)
Tire Pressure, Nose, Heavy Duty, 6 inch
Tire Pressure, Main, Heavy Duty, 6 inch
Fixed
Combination Air and Or1
MIL-H-5606
3.50 2 .50 in.
4.50 t .SO in.
7 ft. 8 in.
30° Left & Right
59 ft. 10.8 in.
Cleveland 40-778 or
McCauley D-30500
Cleveland 40-90A Standard or
Cleveland 417- 120C H e a ~ yDut!
Cleveland 30-65 Standard or
Cleveland 30-83 Heav! Duty
5.00 x 5, 6 ply, Type Ill. McCrear or
B.F. Goodrich
6:00 x 6, ply, Type 111. McCrear! or
B.F. Goodrich (Optronal)
6:00 x 6. 8 ply. McCreary or
6:00 x 6. 8 ply, B.F. Goodrrch
(Heavy Duty)
35 psi
55 psi
33-35 psi
35-37 psi
34 psi
46 psi
C
6- 10-00
Page 6-03
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
'MAINTENANCE MANUAL
Figure 6-1. Three View of PA-32301
6.1&00
Page 6-04
Revised: August 19, 1980
PIPER AIRCRAFT
PA-32=301/301T
*MAINTENANCE M A N U A L
1
0
5
n
Figure 6-2. Three View of PA32301T
6-10-00
p 8 6-05
~
Revised: May 21,1980
PIPER AIRCRAFT
PA-3L-301/301T
'MAINTENANCE MANUAL
STATION REFEREKCE LIKES.
In order to facilitate the location of various components of the airplane which require maintenance and
servicing. a method utilizing fuselage station (Sta.), wing station or buttock line (BL). and water line (WL)
designations is frequently employed in this manual. (Refer to Figure 6-3 or 6-4.) Fuselage stations. buttock
lines. and water lines are reference points measured by inches in the vertical or horizontal direction from a
given reference line which indicates station locations of structural members of the airplane. Station 0 of the
fuselage is 78.4 inches ahead of the wing leading edge or 44.5 inches ahead of the lower edge of the fireuall:
station 0 (BL) of the wing and stabilator is the centerline of the airplane; and station 0 (WL) of the fuselage
vertical stabilizer and rudder is 20.5 inches below the cabin floor as measured at the rear wing spar with the
airplane level. The reference datum line is located 78.4 inchesahead of the wing leading edge at the intersection
of the straight and tapered section.
ACCESS A N D INSPECTION PROVISIONS.
I
The access and inspection provisions for the airplane are shown in Figure 6-5. The component to be
seniced or inspected through each opening is identified in the illustration. All access plates and panels are
secured by either metal fasteners or screws. T o enter the aft section of the fuselage, remove the rear close-out
access door.
- CAUTION Before entering the aft section of the fuselage, be sure the airplane is
supported at the tail skid.
WEIGHT A N D BALANCE DATA.
When figuring various weight and balance computations. the empty. static and gross weight. and center of
gravity of the airplane may be found in the Weight and Balance Form of the Airplane Flight Manual.
SERIAL NUMBER PLATE.
The serial number plate is located on the left side of the fuselage near the leading edge of the stabilator.
The serial number should always be used when referring to the airplane on service or warranty matters.
6-50-00
Page 6-06
Revised: May 21, 1980
PIPER AIRCRAFT
PA-32-30 1 /30 1T
*MAINTENANCE M A N U A L
Figure 6-3. Station Reference Lines (PA-32-301)
6-5&00
Page 6 0 7
Revised: August 19, 1980
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
Figure 6-4. Station Reference Lines (PA-32-301T)
650-00
Page 6-08
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 1301T
*MAINTENANCE MANUAL
+
2859
1
1
1
8
9
2
I
0
m
I
1
2
3
4
5
6
7
8
9
10
11
12
TIP STABILATOR
COWL. ENGINE ACCESS
SPINNER PROPELLER
DOOR. OIL FILLER
COVER AIR FILTER
COVER. ACCESS (PA-32-3011)
FAIRING. ACCESS
FIN TIP
RUDDER TIP
PANEL. BATTERY
PLATES. TUNNEL ACCESS
PANEL. FLOOR
n
22 23
13
14.
15
16
17
18.
19.
20.
21.
22.
23.
COVER. FUEL SELECTOR FILTER
TAIL CONE. CONTROL CABLES & TRIM SCREW
WlNG TIP
COVER, E L T ACCESS
COVER, AILERON BELLCRANK ACCESS
COVER. GEAR ATTACHMENT FllTlNG
DOOR. BAGGAGE
CAP, FUEL TANK
COVER, FUEL FITTING
COVER. FUEL AND BRAKE FITTINGS
COVER. FUEL FITTINGS
Figure 6-5. Access Plates and Panels
6-50-00
Page 6-09
Revised: August 19. I 980
a
CHAPTER
LIFTING AND SHORING
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
-
CHAPTER 7 LIFTING A N D SHORING
TABLE OF CONTESTS/EFFECTlVITY
CHAPTER
SECTIOK
SL'BJECT
GRID
SUBJECT
NO.
EFFECTII.ITY
-
7 Cont./Effec.
Page 1
Revised: August 11 1983
-
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
Figure 7-1. Jacking
JACKISG.
Jack the airplane as specified to perform \arious service operations. Proceed as folloufs:
I. Place the jacks under the jack pads on the wing front spar.
- CAUTION Be sure to apply sufficient support ballast; otherwise, the airplane
will tip forward and fall on the fuselage nose section.
2. Attach a tail support t o the tail skid. Place approximately 300 pounds of ballast on the support to
hold the tail d o n n. ( Refer to Figure 7-1 .)
3. Carefull! rake jacks until all three wheels are clear of the surface.
-- END
-
7- 10-00
Page 7-01
Revised: August 11. 1983
CHAPTER
LEVELING AND WEIGHING
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
•
-
CHAPTER 8 LEVELING A N D WEIGHING
TABLE O F CONTENTSIEFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
8-10-00
LEVELING
8-20-00
WEIGHING
GRID
NO.
EFFECTIVITY
-
8 Cont./Effec.
Page 1
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301/30lT
*MAINTENANCE MANUAL
LEVELING.
All configurations of the airplane are provided with a means for longitudinal and lateral l e ~ e l ~ nThe
g.
airplane may be le\eled while on jacks. during the weighing procedure while the wheels are on scales. or w hile
the wheels are on the ground. T o level the airplane for purposes of weighing or rigging. the following
procedures may be used:
I. T o longitudinally level the airplane. partially withdraw the two leveling screws located immediately
below the left front side window. (Refer to Figure 8-1.) Place a spirit level on these screw heads and deflate the
nose wheel tire or adjust the jacks until the bubble of the level is centered.
2. T o laterally level the airplane. place a spirit level across the baggage compartment floor along the rear
bulkhead (refer t o Figure 8- 1 ) and deflate the tire on the high side of the airplane or adjust eitherjack u n t ~the
l
bubble of the level is centered.
Longitudinally
Laterally
Figure 8- 1. Leveling Airplane
8-10-00
Page 8-01
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
.MAINTENANCE MANUAL
WEIGHISC. (Refer to Figure 8-2.)
The airplane ma! be weighed b! the following procedure:
I . Posit~ona scale and ramp in front of each of the three uheels.
2. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to T o u ~ n g .
Chapter 9.)
3. Remove the ramp so as not to interfere with the scales.
4. If the airplane is to be weighed for weight and balance computations. lekel the airplane.
8-20-00
Page 8-02
Revised: August 11, 1983
CHAPTER
TOWING AND TAXIING
PIPER AIRCRAFT
PA-32-.301/301T
MAINTENANCE MANUAL
-
CHAPTER 9 TOWING A N D TAXIING
TABLE OF CONTEh'TS/EFFECTIVITY
CHAPTER
SECTIOK
SUBJECT
SUBJECT
-
GRID
NO.
EFFECTIVITY
-
TOWISG
TAXIING
-
9 Cont./Effec.
Page 1
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301/301 T
*MAINTENANCE MANUAL
TOWING.
W'hen towing with power equipment, do not turn the nose gear in
either direction beyond its steering radius limits as this will result in
damage to the nose gear and steering mechanism. Whenmoving the
aircraft forward by hand, avoid pushing on the trailing edge of the
ailerons as this will cause the aileron contour to change resulting in
an out-of-trim condition.
T h e airplane may be moked by using the nose wheel steering bar that is stowed below the foruard ledse of
the rear baggage compartment o r power equipment that will not damage or cause excessstrain to the nose pear
steering assembly.
Before attempting t o taxi the airplane. ground personnel should be checked out by a qualified p ~ l o tor
other responsible person. Engine starting a n d shutdown procedures should be covered as \\ell. \\ h e n 11 i\
ascerta~nedthat the propeller back blast and taxi areas are clear. apply power to start the taxi roll and pert'orm
the follouing checks:
1 . Taxi forw.ard a few. feet and apply brakes t o determine their
effectikeness.
2 . Taxi with propellers set in lou pitch. high R P M setting.
3. ii'hile taxiing. make slight turns t o ascertain the effecti\eness of steering.
4 . O b s e n e wing clearances w hen taxiing near buildings o r other stationary objects. If poss~ble4tat1onil
guide outside the airplane to obser\.e.
5 , \'hen taxiing on uneven ground. look for and avoid holes and ruts.
6 . D o not operate the engines at high R P M u h e n running up o r taxiing o \ e r ground containing looye
stones. gra\el. o r an!. loose material that ma?. cause damage t o the propeller blades.
- END -
9- 20-00
Page 9-01
Revised: August 11. 1983
a
CHAPTER
PARKING AND MOORING
PIPER AIRCRAFT
P.4-32-301/301T
MAINTENANCE M A S I ' A L
•
-
CH.-\PTER I0 PARKISC, A S D XlOORIUC,
CHAPTER
SECTIO\
S\H.IECT
GRID
S1'B.I ECT
I 0- 10-00
PARKIKG
10-20-00
MOORIKG
10-30-00
1.OCKlSG AIRPLAKE
\ 0.
EFFECTIi I T )
10 - Cont./Effec.
Page I
Revised: August 1 1. 1983
-
PIPER AIRCRAFT
PA-32-301/301T
'MAINTENANCE MANUAL
H'hen parking the airplane. insure that it is sufficiently protected against adt.erse weather conditions and
presents no danger to other aircraft. When parking the airplane for any length of time or oternight. it i 3
recommended that it be moored.
1 . To park the airplane. head it into the wind. if possible.
2. Set the parking brake by pulling back the brake lever and depressing the knob attached to the left side
of the handle. Then release the handle. T o release the parking brakes. pull back on the brake leter to disengage
the catch mechanism. Then allow the handle t o swing forward.
- NOTE Care should be taken when setting brakes that are overheated or
during cold weather when accumulated moisture may freeze the
brakes.
3. The aileron and stabilator controls may be secured with the pilot's seat belt.
MOORISG.
The airplane is moored to insure its immovability. protection. and security under ~ a r i o u surather
conditions. The following procedure gives the instructions for proper mooring of the airplane:
I . Head the airplane into the wind. if possible.
1. Block the u heels.
3. Lock the aileron and stabilator controls by looping the pilot's seat belt around wheel.
-- CAUTION
-
Use square or bowline knots. D o not use slip knots.
Secure tie-down ropes t o the wing tie-down rings and the tail skid at approximatel!. 45 degree angles to the
ground. N'hen using rope constructed of non-synthetic material. leave sufficient slack to a\.oid damage to the
airplane when the ropes contract due to moisture.
A dditional preparations for high winds include using tie-down
ropes from the landing gear forks, securing the rudder, and securing
the props to prevent windmilling.
LOCKING AIRPLANE.
For con\,enience. the PA-32-301J301T aircraft are provided with matching ignition and door locks.
(Forward cabin door. forward baggage compartment door. and rear cabin door.) One key fits all locks.
- END 10-30-00
Page 10-01
Revised: May 21. 1980
CHAPTER
REQUIRED PLACARDS
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANC'AL
•
CH.4PTER I 1
CHAPTER
SECTIO\
SI'R.1ECT
!
I 1-00-00
- REQl'IRED PLAC.4RDS
SI'RJ ECT
GEYERAL
GRID
YO.
EFFECTI\ IT1
ICI!
.A 6-H-l
Il
- Cont. 1 Effec.
Paze - 1
Revised: .August 9. 1984
PIPER A I R C R A F T
PA-32-301 /301T
MAINTENANCE .M.AVt'A L
GE\ER.\I.
*301TONLY
\
I
I
Figurc I I- I . Placard, and Decal,
11-2&00
Page 11-01
Revised: .Augu\t 9. 1984
PIPER AIRCRAFT
PA-32-301 1301 T
!tlAISTENANCE M A N l ' A L
-
1. PLACARD PIPER-AIRE
2 NAMEPLATE - SARATOGA
3. PLACARD - OXYGEN B O T L E INSTAWTION
4. MEDALLION PIPER LOGO
5. PLACARD AIR CONDITIONING DOOR OPEN
6 . PLACARD - FLAP WARNING
7. PLACARD COMPASS
8. PLACARD OPEN
9. PLACARD LATCH
10. PLACARD LIGHT SWITCH
1 1. PLACARD STORM WINDOW
12. PLACARD OLEO SERVICE INSTAUATIONS
13. PLACARD TURN LIMIT
14. PLACARD TURN LIMIT CENTER MARK
15. PLACARD OLEO SERVICE INSTRUCTIONS
16. PLACARD SOFT WEAR ONLY
17. PLACARD RUDDER TRIM
18. PLACARD LANDING CHECKLIST, KNOTS
19 PLACARD RADIO POWER. "ON-OFF"
20. PLACARD - WARNING
21. PLACARD STABllATOR TRIM
22. PLACARD - EMERGENCY BUS SWITCH
23 PLACARD FUEL SELECTOR
24. PLACARD OPERATING LIMITATIONS
25. PLACARD BAGGAGE LIMITATIONS. FORWARD
26. PLACARD BAGGAGE LIMITATIONS. A n
27. PLACARD - CABIN AIR
28. PLACARD AIR CONDITIONING CONTROL PANEL
29. PLACARD VENT FAN CONTROL
30. PLACARD REDUCE POWER
31. PLACARD HEATER AND DEFROST f L l n TO ACTUATE)
32. PLACARD PlTOT DRAIN
33. PLACARD ALTERNATE AIR
34. PLACARD DEMONSTRATED CROSSWIND
35. PLACARD NAVIGATION AND INSTRUMENT LIGHTS
36 PLACARD - PRESS TO TEST
37 MEDALLION PIPER. CONTROL WHEEL
38. PLACARD - WARNING
39. PLACARD - OXYGEN GAUGE LIGHT
-
-
-
-
40. PLACARD OXYGEN "PULL ON"
41. PLACARD CONTROL QUADRANT
42. PLACARD FUEL GRADE
43. PLACARD A/P INTR.
44. PLACARD MIKE
45. PLACARD - CIRCUIT BREAKER PANEL
46. PLACARD CIRCUIT BREAKER PANEL
47. PLACARD PITCH TRIM
48. PLACARD AUTOFLITE II
49. PLACARD OMNl COUPLER SWITCH
50. PLACARD CONDUCT TRIM CHECK (13A660-1)
51. PLACARD RADAR ALTIMETER "ON-OFF"
52. PLACARD RADAR ALTIMETER "OFF FOR TAKEOFF"
53. PLACARD RADAR ALTIMETER
54. PLACARD WARNING
55. PLACARD ALTITUDE REPORTER INSTALLED
56. PLACARD FUEL CHECK B O l l L E
57. PLACARD SUMP DRAIN
58. PLACARD FLAP LEVER
59. PLACARD ALTITUDE LEANING LIMITATIONS
60.PLACARD TABLE STOWAGE
61. PLACARD ELT LOCATION
62. PLACARD - EXTERNAL POWER
63. PLACARD GLIDE SLOPE COUPLER
64 PLACARD WARNING. EL1
65. PLACARD - RADAR
6 6 PLACARD . DO NOT PUSH
6 7 PLACARD - LEVEL POINT
68 PLACARD hi0 STEP
69 PLACARD - DOOR RELEASE
7 0 PLACARD . DOOR RELEASE
7 1 PLACARD . OIL SPEC
72 PLACARD . NAV 1 OFF NAV 2
73 PLACARD - TRANSPONDER IDENTIFIER PITCL( S Y k C
7 4 PLACARD . GO-AROUND
75 PLACARD - GEAR
76 PLACARD . ON.OFF
77 DECAL - AVGAS ONLY 1000002'
7 8 PLACARD . AUTOPILOT
79 PLACARD - COMPASS SYSTEM
-
-
Figurc I 1-1. Placards and Decals (cont)
1 1-20-00
Page 1 1 -02
Re\ ised: Augurt 9. 19X4
I
I
i
CHAPTER
SERVICING
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
•
-
CHAPTER I2 SERVICING
TABLE OF COh'TEh'TS/EFFECTIVITY
CHAPTER
SECTIOS
SLBJECT
SUBJECT
GRID
NO.
EFFECTI\'ITY
REPLENISHING
Fuel System
Filling Fuel Tanks
Draining Moisture From Fuel System
Draining Fuel System
Oil S!,stem
Sen icing Oil System
Draining Oil Sump
Filling Oil Sump
Oil Screen (Suction)
Recommendations for Changing Oil
Oil Filter (Full Flou)
SCHEDULED SERVlClSG
Sen icing Fuel System
Sen icing Landing Gear
Set\ icing Oleo Struts
Filling Sose Gear Oleo Strut
Filling Main Gear Oleo Strut
Inflating Oleo Struts
Brake System
Sen lclng Brake System
Filling Brake Cylinder Resenoir
Draining Brake System
Tires
Senicing Tires
Tire Balance
Poner Plant
Senicing Poner Plant
Eng~neAir Filter
S e n icing Propeller
Electrical System
Senicing Electrical System
Battery Servicing
Battery Box Corrosion Prevention
Lubrication Instructions
Application of Oil
Application of Grease
Lubrication Chart
Winterization Plate
-
12 Cont./Effec.
Page - 1
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
'MAINTENANCE MANUAL
GENERAL.
This chapter contains routine handling and servicing procedures that are most frequently encountered.
Frequent reference to this chapter will aid the individual by providing information such as the location of
various components. ground handling procedures. routing service procedures and lubrication. When any
system or component requires service other than the routine procedures as outlined in this section. refer to the
appropriate section for that codponent.
REPLENISHING.
FUEL SYSTEM.
FILLING FUEL TANKS.
The fuel tanks of each wing are filled through filler necks located on the forward slope of the wings. Each
wing tank holds a capacity of 53.5 U.S. gallons. Obsente all required safety precautions for handling gasoline.
Fill the tanks with fuel as specified on the placard adjacent to the filler neck.
DRAINING MOISTURE FROM FUEL SYSTEM.
The fuel system should be drained daily prior to first flight and after refueling to avoid the accumulation
of water sediment. Each fuel tank is equipped with an individual quick drain located at the lower inboard rear
corner of the tank. The fuel selector valve is provided with a quick drain valve (refer to Figure 12- I ) and is
located aft of the spar box. Drain fuel tanks and fuel selector valve per the following:
I . Drain each tank through its individual quick drain located at the lower inboard rear corner of the
tank. making sure that enough fuel has been drained to insure that all water and sediment is removed.
To minimize the possibility of &unagihg the jhrsh type fuel tank
dram, use only the fuel sampler specified in Piper Parts Catalog
(Fud Tank Assemblies).
2. Place a container under the fuel selector valve drain. Drain the fuel selector valve by pushing down on
the quick drain handle located on the forward face of the spar box.
3. Examine the contents of the container placed under the fuel strainer drain for water and sediment and
dispose of the contents.
- CAUTION -
When draining m y amount of fuel, care should be taken to insure
that no fire hazard exists k j o r e darting m g k .
After each use of the quick drain w o k , check thefuel selector valve
dram to ensure that the quick drain valve has properly seated and
that there is no loss of fuel from the drain.
12-11-02
Page 12-01
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
+MAINTENANCE MANUAL
\-/'
1 . FILTER
2. SPRING
3. RETAINER WASHER
4. BOWL
NYLON FILTER ASSEMBLY
Figure 12- 1. Fuel Filter Bowl and Screen
1
DRAINING FVEL SYSTEM.
Fuel ma!. be drained from the system by opening the valve at the inboard end of each fuel tank. The tlu3h
type drain \she requires the drain cup pin t o hold the v a l ~ eopen. T h e remaining fuel in the s!stem ma! be
drained through the filter bowl. Any individual tank may be drained by closing the selector \ al\ e and then
draining as desired.
12-1 1-03
Page 12-02
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
I
SERVICING OIL SYSTEM.
The engine oil level should be checked before each flight and changed after each 50 hours of engine
operation. During oil change. the oilscreen(s)should be removed and cleaned. and when installed. the oil filter
cartridge replaced. Inter\.als between oil changes can be increased as much as 1005 on engines equipped u ith
full flow (cartridge t!.pe) oil filters provided the element is replaced each 50 hours of operation. Should fuel
other than the specified octane rating for the power plant be used. refer to latest re\.ision Lycoming S e n ice
Letter S o . L 185 for additional information and recommended service procedures. The engine manuf;lcturer
does not recommend oils by brand names. Use a quality brand Aviation Grade Oil of the proper season
viscosity. For information on the use of detergent oil. refer to Recommendations for Changing Oil and or the
latest re\-ision of Lycoming Service Instruction No. 1014.
D o not introduce any trade additive to the basic lubricant unliss
recommended by the engine manujacturer.
To drain the oil sump. provide a suitable container with a minimum capacity of that required to fill the
sump. Remo\.e the engine cowl and open the oil drain valve located on the underside of the engine b! pushins
the arms of the drain up and turning counterclockwise. This will hold the drain in the open pos~tion.I t is
recommended the engine be warmed to operating temperature to insure complete draining of the old oil.
FILLING OIL SLMP.
The oil sump should normally be filled with oil to the mark on the engine dipstick. The quantit! of oil
required for the engine may be found in Chapter 6. The specified grade of oil may be found in Chart 1202. the
Lubrication Chart. or on the right cowl panel or each engine oil filler access door. To senice the engine 11 irh
oil. open the quick release access door on top of the cowl and remove the oil filler cap with dipstick.
OIL SCREEN (SVCTION).
The oil suction screen. located on the bottom aft end of the engine sump is installed horizon tall^. T o
remo\e. cut the safety wire and remove the hex head plug. The screen should be cleaned at each oil change to
remove any accumulation of sludge and t o examine for metal filings or chips. If metal particles are found in the
screen. the engine should be examined for internal damage. After cleaning and inspection. place the screen
inside the recess in the hex head plug. to eliminate possible damage t o the screen. Insert the screen into the
housing and when certain that the screen is properly seated. tighten and safety the plug with MS-20995-C4 1
safety u ire.
12- 12-04
Page 12-03
Revised: August 11. 1983
1I
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
RECOMMESDATIONS FOR CHANGING OIL. (Refer to the latest re\ision of Lycoming S e r \ ~ c e
Instruction S o . 1014 and Lycoming Senice Letter No. L185.)
I . In engines that have been operating on straight mineral oil for several hundred hours. a change to
additive oil should be made with a degree of caution. since thecleaningaction of some additive oils will tend to
loosen sludge deposits and cause plugged oil passages. When an engine has been operating on straight mineral
oil and is known, to be in excessively dirty condition. the switch t o additive or compounded oil should be
deferred until after the engine is overhauled.
2. When changing from straight mineral oil to compounded oil. the following precautionary steps
should be taken:
A. D o not add additive oil to straight mineral oil. Drain the straight mineral oil from the engine and
fill with additive oil.
B. D o not operate the engine longer than five hours before the first oil change.
C. Check all oil screens for evidence of sludge or plugging and change oil ever); ten hours if sludge
conditions are evident. Resume normal oil drain periods after sludge conditions improve.
OIL FILTER (FULL FLOW).
I . The oil filter should be replaced after each 50 hours of engine operation: this is accomplished b!
removing the lockwire from the bolthead at the end of the filter housing. loosening the bolt. and r e m o ~Ing the
filter assembly from the adapter.
2. Before discarding the throwaway filter. remove the element for inspection by using a Champion
cutter tool. CT-470. available from Champion Spark Plug Co.. Toledo. Ohio 43601. I t hill cut open an\ spin
on t!,pe oil filter for inspection. Examine the material trapped in the filter for evidence of internal englne
damage. such as chips or panicles from bearings. In new or newly overhauled engines. some small particles of
metallic shavings might be found: these are generally of no consequence and should not be confused u ~ t h
panicles produced by impacting. abrasion or pressure. Evidence of internal engine damage found in the oil
filter justifies further examination t o determine the cause.
3. After the filter has been replaced. tighten the cartridge within 18 to 20 foot-pounds of torque.
Lockwire the bolt through the loops on the side of the housing t o the drilled head of the thermostatic \ she. Be
sure the lockwire is replaced at both the attaching bolthead and the thermostatic oil cooler bypass \ a h e. L'se
MS-20995-C41 safety wire.
12-12-06
Page 12-04
Revised: August 11,1983
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
SCHEDULED SERVICING.
SERVICING FUEL SYSTEM.
1 . At intervals of 50 hours or 90 days. whichever comes first. clean the fuel screen in the inlet side of the
injector and the fuel selector valve screen.
2. T o flush the fuel tanks and selector valve. disconnect the fuel line at the injector.
3. Select a fuel tank. turn on the electric fuel pump and flush fuel through the system until i t is
determined there is no din and foreign matter in the fuel valve or tank. During this operation. agitation of the
fuel within the tank will help pick up and remove any din.
4. Repeat this procedure for each tank.
5 . When all tanks are flushed. clean all filters.
The PA-32-301/301 T aucrajt are wproved for operation with an
anti-icing addilive in thejuel. When an anti-icing additive is used it
must meet the specgication MIL-I-27686, must be uniformly
blended with the juel while rqfueling, must not exceed .IS% by
volume of the refueled quantity, and to insure its effectiveness
should be blended at not less than .1 0%by volume (oneand one-half
liquid 02s. per ten gallon of fuel would be within the range). A
blender supplied by the additive manufacturer should be used.
Except for the information contained in this section, the
manufacturer's mixing or blending instructions should be carefully
followed.
-- CAUTION
-
Assure that the additive is dbected into flowing fuel stream. The
additiveflow should start after andstop before thefueljlow. Do not
permit the concentrated additive to mme in contact with the aircraft
painted surfaces or the interior suqfaces of the juel tanks.
Some fuels have anti-icing additives pre-blended in the fuel at the
refinery, so no further blending should be performed.
Fuel additive cannot be used as a substitutefor a prejlight draining
of the juel system drains.
Page 12-05
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
SERVICING L A S D I S C GEAR.
The landing gear consists of tires. brakes. oleo strut assemblies and. on some models. u heel fairings.
'These should be inspected for scored piston tubes. possible hydraulic fluid leakage. security and condition of
all connection points. and the fairings for cracks. Check the brake linings for wear and frayed edges and brake
discs for scoring. Replace if found necessap. Minor senicing is described in the following paragraphs. For
detailed serLices and o ~ e r h a u linstructions. refer to Chapter 32.
1. FILLER. MAlN FUEL TANK, RIGHT
2. DRAIN. MAIN FUEL TANK. RIGHT
3. FILTER. FUEL PUMP. ELECTRIC
4 . CARTRIDGE FILTER, ENGINE OIL
5. FILLER/INDICATOR, OIL, ENGINE
6. PROPELLER
7. LINK ASSEMBLY. NOSE
8. TIRE. NOSE
9. FILLER. OLEO SHOCK STRUT. NOSE
10. SCREEN. OIL SUCTION. ENGINE
11. BATTERY (PA-32-301)
12. RESERVOIR. BRAKE SYSTEM
13. DRAIN. FUEL
14. DRAIN. MAlN FUEL TANK. LEFT
15. FILLER. OLEO SHOCK STRUT, MAlN
16. TIRE. MAlN
17. FILLER. MAlN FUEL TANK. LEFT
18. FILTER, VACUUM REGULATOR AND CENTRAL AIR
19. BAlTERY (PA-32-3011)
Figure 11-2. Senicing Points
12-22-00
Page 12-06
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
*MAINTENANCE MANUAL
SERVICING OLEO STRCTS.
Air-oil struts are incorporated in each landing gear oleo to absorb the shock resulting from the impact of
the wheels on the runway during landing. T o obtain proper oleo action. the nose gear oleo strut must h a \ e
approximately 3.25 t .25 inches of piston tube exposed. while the main pear struts require approximately 4.5 2
.5O inches of tube exposure.
- CAUTION D o not exceed these t u k exposures.
These measurements are taken with theairplane setting on a level surface under normal static load (empty
weight of airplane plus full fuel and oil). If the strut has less tube exposed than that prescribed. determine
whether it needs air or oil by raising theairplane on jacks. With thestrut extended. remove the cap from the air
valve at the top of the housing and depress the valve core to allow air t o escape from the strut piston until it is
fully compressed. Allow the foam from the air-oil mixture to settle and then determine if oil is visible up to the
bottom of the filler plug hole. If oil is visible at the bottom of the hole. then all that is required is the \.al\e be
checked for unsatisfactory conditions and air added as described in Inflating Oleo Struts. Should fluid be at
any level below the bottom of the filler plug hole. the oleo should be checked for leaks. etc.. and oil added as
described in Filling Nose Gear Oleo Strut for the nose gear or Filling Main Gear Oleo Strut for the main gear.
For repair procedures of the landing gear a n d / o r oleo struts. refer to Chapter 32.
- WARNING Do not release air by removing the strut vabe core or filler plug.
Depress the vahe core pin until strut chamber pressure has
diminished.
- C AUTION Dirt andloreign particles/orm around thefiller plugs of the landing
gear struts, therefore, before attempting to remove theseplugs, the
tops of the struts should be cleaned with compressed 4C and/or with
a dry solvent.
FILLING NOSE GEAR OLEO STRUT. .
T o fill the nose gear oleo strut with hydraulic fluid (MIL-H-5606). whether it be only the addition of a
small amount or if the unit has been completely emptied and will require a large amount. it should be filled as
follows:
I . Raise the airplane on jacks until the nose wheel is completely clear of the ground. (Refer to Chapter
7.)
2. Place a pan under the p a r t o catch spillage.
3. I f not previously accomplished. remove the engine cowl and relieve air from the strut housing
chamber by removing the cap from the air valve and depressing the valve core.
Page 12-07
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
4. There are two methods by which the strut chamber may be filled and these are as follows:
Method 1.
A. Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to
remain installed.
B. Attach one end of a clear plastic hose to the valve stem of the filler plug and submerge the other
end in a container of hydraulic fluid. Ascertain that the end of the hose on the valve stem is tight and the f l u ~ d
container is approximately equal in height t o the top of the strut housing.
C. Fully compress and extend the strut thusdrawing fluid from the fluid container and expelling air
from the strut chamber. By watching the fluid pass through the plastic hose. it can be determined when the
strut is full and no air is present in the chamber.
D. When air bubbles cease to flow through the hose. compress the strut fully and remove the hose
from the valve stem.
E. With strut compressed. remove the filler plug to determine that the fluid level is visible up to the
bottom of the filler plug hole.
F. Reinstall the core in the filler plug and apply thread lubricated (Parker #6PB) to the threads of
the filler plug and install the plug in the top of the strut housing. Torque the plug to 45 foot-pounds.
Method 11.
A. Remove the filler plug from the top of the strut housing.
B. Raise the strut piston until it is fully compressed.
C. Pour fluid from a clean container through the filler opening until it reaches the bottom of the
filler plug hole.
D. Install the filler plug finger tight. and extend and compress the strut two or three times to mobe
any air that may be trapped in the housing.
E. Remove the filler plug. raise the strut to full compression and fill with fluid if needed.
F. Apply thread lubricant (Parker #6PB) to the threads of the filler plug. Reinstall the filler plug
and torque to 45-foot pounds.
5. With the airplane raised. compress and extend the gear strut several times to ascertain that the strut
actuates freely. The weight of the gear fork and wheel should extend the strut.
6. Clean off overflow of fluid. and inflate the strut as described in Inflating Oleo Struts.
7. Check that fluid is not leaking from around the strut piston at the bottom of the housing.
FILLING MAIN GEAR OLEO STRUT.
A main gear oleo strut that is partly full or one that has been completely emptied may be filled with MILH-5606fluid as follows:
I . Raise the airplane on jacks until the landing gear torque link assembly has almost reached its full
travel. (Refer to Chapter 7.)
2. Place a pan under the gear t o catch spillage.
3. If not previously accomplished. remove a cap on top of the wing to gain access to the top of the strut
housing. and relieve air from the strut housing chamber by removing the cap from the air valve and depressing
the valve core.
12-22-03
Page 12-08
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
*MAINTENANCE MANUAL
4. Remove any one of the three torque link bolts. and again raise the airplane until a minimum of ten
inches (do not exceed twelve inches of tube exposure) of strut tube is exposed with the wheel remaining on the
ground. With this amount of tube exposed. fluid will flow from the middlechamber to the bottom chamber of
the strut housing. insuring that the bottom chamber is filled with fluid.
-- NOTE
-
With the torque links disconnected, the piston tube is free to slidc
from the strut housing.
5.
Fill the main gear housing by one of two methods which are as follows:
Method I.
A. Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to
remain installed.
B. Attach one end of a clear plastic hose t o the valve stem of the filler plug and submerge the other
end in a container of hydraulic fluid.
C. Fully compress and extend (10 + 2-0 inches of strut tube exposed) the strut thus drawing fluid
from the strut chambers. By watching the fluid pass through the plastic hose. it can be determined u hen the
strut is full and no air is present in the chambers. The strut must be extended to full ten inches to allou fluid to
enter the bottom chamber of strut housing.
D. When air bubbles cease t o flow through the hose. compress the strut fully and remo\e the hose
from the valve stem.
E. With the strut fully compressed. remove the filler plug to determine that the fluid \e\ells \ lsible
up to the bottom of the filler plug hole.
F. Reinstall the core in the filler plug and apply thread lubricant (Parker #6PB) to the threads of the
filler plug and install the plug in the top of the strut housing. Torque the plug to 45 foot-pounds.
Method 11.
A. Remove the filler plug from the top of the strut housing.
B. Raise the strut t o full compression.
C. Pour fluid from a clean container through the filler opening until it is visible at the top of the
strut chamber. If the housing has been completely emptied or nearly so. allow sufficient time for the fluid to
drain through the orifice from the upper chamber into the middle chamber.
D. Lower the gear until the wheel touches the ground ( 10 + 2-0 inches of strut exposure) and then
fully compress and extend the strut three or four times to removeany air that may be trapped and to allou fluid
t o enter the bottom chamber of the housing.
E. Raise the strut t o full compression and if needed. fill with fluid t o the bottom of the filler plug.
F. Apply thread lubricant (Parker #6PB) to the threads of the filler plug. Reinstall the filler plug
and torque to 45 foot-pounds.
6. Replace the torque link bolt. Tighten bolt only tight enough t o allow no side play in the connection.
7. With the airplane raised. retract and extend the gear strut several times to ascertain that the strut
actuates freely. The weight of the gear fork and wheel should extend the strut.
8. Clean off overflow of fluid and inflate the strut as described in Inflating Oleo Struts.
9. Check that fluid is not leaking around the strut piston at the bottom of the housing.
12-22-03
Page 12-09
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
Figure 12-3. Main Gear Oleo Struts (Cut-Away View)
12-22-03
Page 12-10
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
INFLATING OLEO STRUTS.
After making certain that the oleo strut has sufficient fluid. attach a strut pump to the air valve and inflate
the oleo strut. The strut should be inflated until the correct inches of piston is exposed with normal static load
(empty weight of airplane plus full fuel and oil) on the gears. (Refer to Servicing Oleo Struts.) Rock the
airplane several times to ascertain that the gear settles back to the correct strut position. (Ifa strut pump is not
available. the airplane may be raised and line pressure from a high pressure air system used. Lower the airplane
and while rocking it. let air from the valve to bring thestrut down to the proper extension.) Before capping the
valve. check for valve core leakage.
BRAKE SYSTEM.
SERVICING BRAKE SYSTEM.
The brake system incorporates a hydraulic fluid reservoir through which the brake system is periodically
serviced. Fluid is drawn from the reservoir by the brake cylinders to maintain the volume of fluid required for
maximum braking efficiency. Spongy brake pedal action is often an indication that the brake fluid reservoir is
running low on fluid. Instructions for filling the reservoir are given in Filling Brake Cylinder Reservoir. When
found necessary to accomplish repairs to any of the brake system components, or to bleed the system. these
instructions may be found in Chapter 32.
FILLING BRAKE CYLINDER RESERVOIR.
The brake cylinder reservoir should be filled to the level marked on reservoir. with MIL-H-5606 fluid. The
reservoir. located on the left side of the firewall in the engine compartment, should be checked at every 50-hour
inspection and replenished as necessary. No adjustment of the brakes is necessary. though they should be
checked periodically per instructions given in Chapter 32.
DRAINING BRAKE SYSTEM.
To drain the brake system. connect a hose to the bleeder fitting on the bottom of the cylinder and place the
other end of the line in a suitable container. Open the bleeder and slowly pump the hand brake lever and the
desired brake pedal until fluid ceases to flow. To clean the brake system. flush with denatured alcohol.
TIRES.
SERVICING TIRES.
The tires should be maintained at the pressure specified in Chapter 6. When checking tire pressure.
examine the tires for wear. cuts. bruises and slippage on the wheel. The tire, tube, and wheel should be properly
balanced when installed with the index mark on the tire aligned with the index mark on the tube.
12-24-01
Page 12-11
Revised: August 11, 1983
a
PIPER AIRCRAFT
PA-32-3C1/301T
MAINTENANCE MANUAL
TIRE BALANCE.
Proper balancing is critical for the life of aircraft tires. If a new tire is balanced upon installation it will
usually remain balanced for the life of the tire without having any shimmy or flat spots. and an inexpensne
balancer can be made that will balance almost any tire for light aircraft. Refer to Chapter 91 for balancer
details. Balance the tire as follows:
I. Mount the tire and tube (if one is used) on the wheel. but d o not install the securing bolts. Install the
wheel bearings in the wheel: then. using the bushings, spacers. and nuts. install the wheel-tire assembly on the
pipe. Secure the nuts finger-tight so that the wheel halves touch each other. Be sure the bolt holes are aligned.
Insert the axle through the pipe and place the wheel in the center of the balancer. Make sure the axle is only on
the chamfered edges of the balancer and that it is at 90° to the sides of the balancer.
2. Release the tire. If it is out of balance it will rotate. coming to rest with the heaviest point on the
bottom. Tape a 112 ounce patch across top center of the tire. Rotate the tire 4 5 O and release it again. I f the tire
returns to the same position, add a 1 ounce patch and again rotate the tire and release it. Continue this
procedure until the tire is balanced.
3. When balance is attained. put achalk mark on the sidewall directly below the patch. Use one mark for
each half ounce of weight needed. Mark the valve stem location on the tire and the opposite wheel half to
assure reassembly in the same position. Remove the wheel from the balance stand. break it down and clean the
inside of the tire with toluol. Apply a coat of patch cement to both the patch and the insidecenter of the tire In
line with the chalk marks. When the cement has dried. install the patches makingcenain they are on the center
line of the tire and aligned with the chalk marks on thesidewall. Burnish the patches to remove trapped air. etc.
4. When reassembling the wheel. powder the inside of the tire. Mount the tire on the vahe side of the
wheel in the same position it was in when it was balanced. Install the other wheel half. aligning the chalk marks.
Install the bolts and tighten to required torque. then air the tireand recheck the balance. The wheel should not
be more than 1 2 ounce out of balance.
THIS SPACE INTENTIONALLY LEFT BLANK
12-24-02
Page 12-12
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
POWER PLANT.
SERVICING POWER PLANT.
Regularly check the engine compartment for oil and fuel leaks, chafing of lines. loose wires and tightness
of all pans. For cleaning of the engine compartment, refer to Chapter 20.
ENGINE AIR FILTER.
1.
Removing Engine Air Filter
A. Remove the front cowl scoop.
B. Unfasten the quarter-turn fastener securing the filter.
2. Cleaning Engine Air Filter
The induction air filter should be checked during each preflight inspection and cleaned or
replaced if found to be dirty. Replace the filter after one year, after ten cleanings or 500 flight hours.
whichever comes first.
To clean the filter:
A. Blow compressed air through the filter in the opposite direction of normal airflow to remo\e
light dust contaminants. Air pressure is to be less than 100 psi and keep the nozzle at least one inch from the
filter to prevent damage.
B. If the filter is excessively dirty, flush filter with running water (less than 40 psi) and soak ~t in a
solution of Donaldson D-1400 compound and water. Do not use solvents or gasoline. Rinse until clear water
comes through the filter.
C. Dry the filter thoroughly before inspection. Mechanical dryers may be used provided the heated
air is circulated and maintained below 180°F. Do not use a light bulb.
D. Inspect filter medium for holes or tears and insure the frame provides a good air seal. Replace
filter if defects are found.
3, Installation of Engine Air Filter
After cleaning or replacing the filter. install the filter in the reverse order of remo\al
SERVICING PROPELLER.
The spinner, back plate and propeller surfaces should be cleaned and inspected frequently for nicks.
scratches. corrosion and cracks. Minor nicks and scratches may be removed as found in Chapter 6 1 . The face
of each blade should be painted when necessary with a flat paint to retard glare. To prevent corrosion. wipe
surfaces with a light oil or wax.
In addition. constant speed propellers should be inspected for grease or oil leakage and freedom of
rotation on the hub pilot tube. T o check freedom of rotation. rock the blade back and forth through the slight
freedom allowed by the pitch change mechanism. Lubricate the propeller at 100 hour intervals in accordance
with the Lubrication Chart.
Additional service information for the propeller may be found in Chapter 61.
12-25-03
Page 12-13.
~ c v i s t d :August 11, 1983
PIPER AIRCRAFT
PA-31-301 /331T
*MAINTENANCE MANUAL
ELECTRICAL S l STEYI.
SERVICISC ELECTRICAL SYSTEM.
S e n Icing the electrical system involvesadding distilled water to the battery to maintain correct electrol! te
leiel. and checking cable connections and for any spilled electrolyte that would lead to corrosion. The securlt!
of all electrical connections should be checked as well as the operation of all lights. general condition of the
generator or alternator and starter. All electrical wires should be inspected for chafing and bare w ires. For
detailed information on this system. refer to Chapter 24 of this manual.
BATTERY SERVICIKC.
BATTERY BOX CORROSION PREVENTION.
The battery should be checked for spilled electrolyte or corrosion at each 50 hour inspection or at least
even. 30 days. whicheker comes first. Should corrosion be found in the box. on the terminals or around the
battery. the battery should be remo\.ed and both the box and battery cleaned by the following procedure:
I . Remot-e the box drain cap from the underside of the fuselage and drain off any electrolyte that ma!
habe o\.eflowed into the box.
- CAUTION D o not allow soda solution to enter battery.
2. Clean the battery and the box. Corrosion effects may be neutralized byappl!inga solution of baking
soda and water mixed to a consistency of thin cream. The application of this mixture should be applied u n t ~all
l
bubbllng action has ceased.
3. Rinse the battery and box with clean water and dry.
4. Place the cap oier the battery box drain.
5 . Reinstall battery. (Refer to Chapter 24 for additional senice information.)
LL'BRICATION INSTRVCTIONS.
Proper lubrication procedures are of immeasurable value both as a means of prolonging the seri-icelife of
the airplane and as a means of reducing the frequency of extensive and expensive repairs. The periodic
application of recommended lubricants to their relevant bearing surfaces. as detailed in the following
paragraphs. together with obsenance of cleanliness. will insure the maximum efficiency and utmost sen.ice of
all moving parts. Lubrication instruction regarding the locations. time intemals. and type of lubricants used
may be found in the Lubrication Chart. T o insure the best possible results from the application of lubricants.
the following precautions should be observed:
I . Lse recommended lubricants. Where general purpose lubricating oil is specified. but unai.ailable.
clean engine oil may be used as a satisfactory substitute.
2. Check the components to be lubricated for evidence of excessive wear and replace them as necessar!.
3. Remove all excess lubricants from the components in order to prevent the collection of dirt and sand
in abrasive quantities capable of causing excessive wear o r damage to bearing surfaces.
12-27-00
Page 12-14
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
'MAINTENANCE MANUAL
APPLICATION OF OIL.
Whene\,er qpecific instructions for lubrication of mechanisms requiring lubrication are not atailable.
0bsen.e the following precautions:
I. Appl!- oil sparingly, never more than enough to coat the bearing surfaces.
2. Since the control cables are sufficiently coated by the manufacturer. additional protection for the
prevention of corrosion is unnecessary.
3. Squeeze the magneto cam follower felts at regular inspection periods. If oil appears on fingers. do not
add oil. I f the felt is d n . moisten with light oil.
-- CAUTION
-
Be careful not to add too much oil, because the excess will be thrown
off during operation and will cause pitting and burning of the
magneto points.
APPLICATION OF CREASE.
Care must be taken when lubricating bearings and bearings surfaces with a grease gun. to insure that gun
is filled with new. clean grease of the grade specified for the particular application before applying lubr~cantt o
the grease f i t t ings.
1 . Where a reservoir is not provided around a bearing. apply the lubricant sparingl! and itipe off an!
excess.
2. Remo\e wheel bearings from the wheel hub and clean thoroughly with a suitable sollent. \\'hen
repacking with grease. be sure the lubricant enters the space between the rollers in the retainer ring. Do not
pack the grease into the wheel hub.
3. Use extra care when greasing the constant speed propeller hub to avoid blowing the clamp ga\hct..
Remove one grease fitting and apply grease to the other fitting until fresh grease appears at the hole of the
remo\ed fitting.
LL'BRICATIOIV CHART.
Each p a n of the airplane to be lubricated. a s depicted on the Lubrication Chart. is indicated b! a
frequency symbol nhich shows the time intervals between lubrications. Application symbols wlth the
frequency symbols show how the lubrication is applied. A parts nomenclature key. referred to b! a number
adjacent to the frequency symbol. identifies the p a n t o be lubricated. Within the frequency symbol is a code
letter which identif~esthe type of lubricant to be used and a special instructions number which gi\es i n s t r u c ~ ~ o n
for lubricating a particular component.
WINTERlZATlON PLATE.
At this time there are no provisions for a winterization plate.
12-28-00
Page 12-15
Revised: August 11. 1983
PIPER AIRCRAFT
I
PA-32-301/301T
*MAINTENANCE MANUAL
C H A R T 1201. T H R E A D LUBRICANTS
J
TYPE O F LUBRICANT
TYPE O F LINE
I
Brakes
M 1L-H-5606
Freon
TT-A-580 o r MIL-T-5544. Anti-Seize Compound
Fuel
MIL-T-5544, Anti-Seize, Graphite Petrolatum
Landing Gear (Air Valve)
6 P B Parker
Oil
MI L - G 4 3 2 , Lubricating Grease
(Gasoline and Oil Resistant)
Pitot and Static
TT-A-580 (JAN-A-669), Anti-Seize Compound
(White Lead Base)
-NOTE
-
Lubricate engine fittings only with the fluid contained in the particular lines.
12-28-00
Page 12-16
Revised: August 11. 1983
I
I
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
CHART 1202. TYPE OF LUBRICANTS
LUBRICANT
SCCCICICATION
PREf ERRED PRODUCT
AND VENDOR
LUBRICATINQ OIL, GENERAL PURPOSE. LOW
TEMPERATURE
LUBRICATINQ O I L AIRCRAFT RECIPROCATINQ
ENQlNE (PISTON) QRADE AS SPECIFIED
8AE 6 0 ABOVE 60°F AIR TEMP.
SAE 40 30' TO 90°F AIR TEMP.
SAE 3 0 0' TO 70°F AIR TEMP.
SAE 2 0 BELOW 10'C AIR TEMP.
MIL-L-6082
HYDRAULIC FLUID PETROLEUM BASE
QREASE. AIRCRAFT AND INSTRUMENT. QEAR
AND ACTUATOR SCREW
QREASE. AIRCRAFT HIGH TEMPERATURE
TEXACO MARFAK ALL
PURPOSE GREASE,
MOBlL QREASE 77
(OR MOBILUX EPZ).
SHELL ALVANIA EP
GREASE 2
PARKER 0-RINQ LUBRICANT
AERO LUBRIPLATE
FlSKE BROS.
REFINING CO.
FLUOROCARBON RELEASE AGENT DRY
LUBRICANT
-
GREASE LUBRICATION QENERAL
PURPOSE AIRCRAFT
SILICONE, COMPOUND
OREASE. A l R C R A n WIDE-TEMPERATURE
MOBlL QREASE 2 8
AEROSHELL GREASE
22
ROYCO 2 2 s
12-28-00
Page 12-17
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-3011301T
'MAINTENANCE MANUAL
SPECIAL INSTRUCTIONS
1.
2.
-
BEARINGS AND BUSHINGS CLEAN EXTERIOR WITH A DRY TYPE SOLVENT BEFORE LUBRICATING.
LUBRICATION POINTS
WIPE ALL LUBRICATION POINTS CLEAN OF OLD QREASE, OIL DIRT,
LUBRICATING.
-
nc..BEFORE
NOTES
1.
SEE THE LATEST REVISION OF LYCOMING SERVICE INSTRUCTIONS NO. 1014 FOR USE OF DETERGENT OIL.
CAUTIONS
1
2.
3.
4.
DO NOT USE HYDRAULIC FLUID WITH A CASTOR OIL OR ESTER BASE.
DO NOT OVERLUBRICATE COCKPIT CONTROLS.
D O NOT APPLY LUBRICANT TO RUBBER PARTS.
DO NOT LUBRICATE CABLES; THIS CAUSES SLIPPAGE.
12-28-00
Page 12-18
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/30 1T
'MAINTENANCE MANUAL
L
COMPONENT
LUBRICANT
'
FREQUENCY
1. OLEO STRUT FILLER POINT
MIL-H-5608
2. UPPER TORQUE LINK BEAAING
MIL-G-23827
100 HRS
3. TORQUE LINK BUSHING
MIL-L-7870
100 HRS
4. TORQUE LINK CONNECTING BUSHING
MIL-G-23827
100 HRS
5. MAIN WHEEL BEARING
TEXACO MARFAX ALL
PURPOSE GREASE OR
MOblL GREASE 77 (OR
MOBlL EP2 GREASE)
100 HAS
RWROCARBON RELEASE
AGENT DRY LUBRICANT
MS-122
100 HRS
'
100 HAS
6. EXPOSED OLEO STRLJT
7. BRAKE RESERVOIR
MIL-H-6608
AS REQUIRED
SPEClAL INSTRUCTIONS
1. M a ~ Wheel
n
Bearings Disassemble and clean with a dry typr solvent. Ascertain thm grease is packed tmween the roller and cone.
Do not pack grease In wheel housing. Wheel boarings r8qure cluning and repacking after exposure to an abnormal quantity of
water.
2. Oleo Struts and Brake Reurvoir Fill par instructions on unit or Containor or rofer to servia manual.
-
-
8131
7
3
Figure 124. Lubrication Chart (Landing Gear, Main)
12-28-00
Page 12-19
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 13011
'MAINTENANCE MANUAL
COMPONENT
LUBRICANT
FREQUENCY
1
OLEO STRUT FILLER POINT
MIL-H-5606 a
2
STEERING BELLCRANK PIVOT POINT
MIL-L-7870
100 HRS
3
SHIMMY DAMPENER PIVOT POINT
MIL-L-7870
100 HRS
4
TORQUE LINK ASSEMBLY
MIL-L-7870
100 HRS
5
NOSE WHEEL BEARING
TEXACO MARFAX ALL
PURPOSEGREASEOR
MOBIL GREASE 77 (OR
MOBlL EP2 GREASE)
100 HRS
AS REQUIRED
6
NOSE GEAR STEERING ROD END BEARINGS
MIL-L-7870
100 HRS
7
STEERING ROD
PARKER O-RING
LUBRICANT
100 HRS
FLUOROCARBON RELEASE
8
EXPOSED OLEO STRUT
2
Oleo Struts F ~ lper
l lnstructlons on u n ~or
t refer to
-
service
manual
Figure 12-5. Lubrication Chart (Landing Gear. h'ose)
11-28-00
Page 12-20
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32=301/301T
@MAINTENANCEMANUAL
I
-- CAUTION
D o not lubricate control wheelor bushings. Clean only with alcohol
or other suitabk solvent.
.
f
COMPONENT
a
-
1.
2.
3.
4.
5.
6
7.
AILERON HINGE BEARINGS
F L A P HINGE BEARINGS
STAB1 LATOR HINGE PINS
RUOOER HINGE BEARINGS
CONTROL CABLE PULLEYS
T R I M CONTROL WHEEL
O-RING, CONTROL SHAFT BUSHINO
I.
9.
TEE B A R PIVOT POINT
CONTROL COLUMN CHAIN
CONTROL COLUMN FLEX. JOINTS A N 0 SPROCKET
STABILATOR CONTROL
10
11.
LUBRICANT
MIL-L-7870
MIL-L-7870
MIL-L-7870
MIL-L-7870
MIL-L-7870
MIL-L-787 0
PARKER O-RING
LUBRICANT
MIL-L-7870
MIL-L-7870
MIL-L-7810
M I L-L-7 87 0
FREQUENCY
100 HRS
100 HRS
100 HRS
100 HRS
100 HRS
100 HRS
AS REQUIRED
100 HRS
500 HRS
100 HRS
100 HRS
1778
SKETCH A
I
4
Figure 126. Lubrication Chart (Control System)
Interim Revision: July 30, 1986
PIPER AIRCRAFT
PA-32-301/301T
'MAINTENANCE MANUAL
.
COMPONENT
1.
2.
3.
4.
6.
7.
F L A P TORQUE TUBE BEARING BLOCFLAP CONTROL ROD E N D BEARINGS
F L A P H A N D L E PIVOT POINT. LOCK MECHANISM
A N D TURNBUCKLE E N D
F L A P R-URN AND TENSION CHAINS
A l ER N
AILERON CONTROL ROD END BEARINGS
AILERON BELLCRANK CABLE ENDS
C338
2
1078
SKETCH A
0
LUBRICANT
FREOUENCY
MILL-7870
MIL-L-7870
100 HRS
100 HRS
MIL-L-7870
MIL-L-7870
MIL-L-7870
MIL-L-7870
MIL-L-7870
100 n R s
SO0 HRS
100 HRS
100 HAS
100 HAS
0008
SKETCH B
Figure 12-6. Lubrication Chart (Control System) (cont)
12-28-00
Page 12-22
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
1.
RUDDER TUBE BEARING BLOCKS
Figure 12-6. Lubrication Chart (Control System) (cont)
12-28-00
Page 12-23
Revised: August 11. 1983
I
I
PIPER AIRCRAFT
I
PA-32-301/301T
*MAINTENANCE MANUAL
2
COMPONENT
1.
2.
CONDENSER HINGE A N D ACTUATORS
CONDENSER DOOR ACTUATING TRANSMISSION
FREQUENCY
LUBRICANT
1 0 0 HRS
5 0 0 HRS
MIL-L-7870
MILC-23127
I
1821
SPECIAL INSTRUCTIONS
Transmlsslon to bo 1R full of gruso. A ~ p l yg r u r durlng
oY.mbIy and l u b r l ~ t otronsmlsslon boll nut m a screw with
MIL-Q-23827 groom.
Figure 12-7. Lubrication Chart (Air Conditioning Condenser)
12-28-00
Page 12-24
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
*MAINTENANCE MANUAL
COMPONENT
,
1.
2.
DOOR HINGES
DOOR SEALS
3.
4.
DOOR LATCH MECHANISMS
SEAT T RACK ROLLERS, STOP PINS A N 0 REAR SEAT
LEO RETAINER (CLIP AND CAM)
5.
SEAT LATCH STOP PIVOT POINT (COPILOT)
STOP SHOULD BE LUBRICATED AND CREE
TO SWIVEL WITHOUT EXCESSIVE PLAV
,
SKETCH A
LUBRICANT
FREQUENCY
MIL-L-1870
FLUOROCARBON RELEASE
AGENT DRY LUBRICANT
MS-122
MI1 -1 -7170
100 HRS
S O HRS
5 0 0 HRS
AERO LuBRIPUTE
MAG.1 FlSKE BROS
REFINING CO
100 HRS
MIL-L-7170
100 HRS
SPECIAL INSTRUCTIONS
Apply tluoroarbon dry lubrlunt t o door u r l c r t ban oncr r
month t o prwrnt thr w r ~
trom stlcklng, and lmprovr U . I I ~ ~
cturrctmrlttlcs.
Figure 12-8. Lubrication Chart (Cabin Door. ~ a i ~ Door
a ~ &
e Seat)
12-28-00
Page 12-25
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
COMPONENT
1.
ENGINE SUMP
2.
3.
4.
5.
6.
CARTRIDGE TYPE OIL FILTERS
A I R FILTERS
PROPELLER ASSEMBLY
ENGINE CONTROL A N D ENVIRONMENTAL
CONTROL PIVOT POINTS
FRESH A l R VENT SHAFTS
7.
ALTERNATOR IDLER PULLEY BEARING
+
LUBRICANT
FREQUENCY
MIL-L6012
LUBRICATING OIL.
AIRCRAFT RECIPROCAT ING ENGINE
(PISTON) GRADE AS
SPECIFIED. SAE 50
ABOVE 60° F Al R
TEMP.. SAE 40 30'
T O 90° F AIR TEMP.,
SAE 30 O0 TO 70° F
A l R T EMP.. SAE 20
BELOW 100 F AI R
TEMP.
1I
50 HRS
MILQ-23127
50 HRS
50 HRS
100 HRS
MIL-L-7870
MIL-G-7711
100 HRS
500 HRS
MIL441322
100 HRS
1
'
J.
)
.
t
'
<-.-,
.
.
*\
i,I,
&;
I
7
SKETCH B
SPECIAL INSTRUCTIONS
1740
1.
4
2.
-
AIR F I L T E R TO CLEAN FILTER, TAP GENTLY TO
REMOVE D I R T PARTICLES. DO NOT BLOW OUT
WITH COMPRESSED AIR OR USE OIL. REPLACE
FILTER I F PUNCTURED OR DAMAGED.
INTERVALS BETWEEN O I L CHANGES C A N BE
INCREASED AS MUCH AS 100% ON E N G I N t 3
EQUIPPED WITH F U L L FLOW (CARTRIDGE TYPE)
PROVIDED THE ELEMENT IS
O I L FILTERS
REPLACED EACH 50 HOURS OF OPERATION.
PROPELLER REMOVE ONE OF THE TWO GREASE
FITTINGS FOR EACH BLADE. APPLY GREASE
T H R O U G H F l T T l N Q U N T I L FRESH GREASE
APPEARS A T HOLE OF REMOVED FITTING.
-
3.
-
NOTE
.'
SKETCH A
SEE LYCOMING SERVICE INST RUCTIONS NO. 1014
FOR USE OF DETERGENT OIL
Figure 12-9. Lubrication Chart (Power Plant. Propeller & Control Pivot Points)
12-28-00
Page 12-26
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
LUBRICANT
COMPONENT
,
1.
2.
FUEL SEL ECTOR LINKAGE
FUEL SELECTOR V A L V E COVER PLATE
MIL-L-7870
FLUOROCARBON RELE&E
AGENT D R Y LUBRICANT
MS-122
FREQUENCY
100 HRS
100 HRS
r
1673
1
f YPICAL
2
Figure 12-10. Lubrication Chart (Fuel Selector)
12-28-00
Page 12-27
Revised: August 11. 1983
CHAPTER
STANDARD PRACTICES/
AIRFRAME
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
-
CHAPTER 20 STANDARD PRACTICES/AIRFRAME
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOX
SUBJECT
SUBJECT
GRID
SO.
EFFECTIVITY
GESERAL
Torque Wrenches
Method of Installing Rod End Bearings
Cherrylock Rikets. Removal
'Identification of Fluid Lines
Installation of Flexible Hose Assemblies
Flareless Tube Assemblies
Support Clamps
AIRCRAFT F l S l S H CARE (CLEANISG)
Exterior Surfaces
Windshield and Windows
Headliner. Side Panels and Seats
Carpets
Engine Compartment
Fuel S\ stem
Landing Gear
-
20 Cont./Effec.
Page 1
Revised: August 1 1. 1983
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
•
GENERAL.
This chapter contains general information pertaining to standard aircraft hardware installation and
removal practices. The information included will be very helpful if it is referred to on a regular basis.
For standard repair practices of a minor nature, refer to AC43.13.
If repairs dictate Non-Destructive Testing (N.D.T.) after repair such as welding, magniflux should be
used on materials made from 4130 steel such as engine mounts and seat frames.
Testing and inspecting of aluminum castings and machined aluminum pans may be accomplished by the
dye penetrant method.
Usually. a good visual inspection with 10X magnifying glass will show any damage or defect in a repair
that is of a significant nature.
TORQUE WRENCHES.
Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to
make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and
is not recommended. Some wrenches are quite sensitive a s to the way they are supported during a tightenme
operation. Any instructions furnished by the manufacturer must be followed explicitly.
When it is necessary to use a special extension or adapter wrench together with a torque wrench. a simple
mathematical equation must be worked out to arrive at thecorrect torque reading. Following is the formula to
be used: (Refer to Figure 20- I .)
T =Torque desired at the part.
A = Basic lever length from center of wrench shank to center of handle or stamped on wrench or listed for
that model wrench.
B = Length of adapter extension, center of bolt to center of shank.
C =Scale reading needed to obtain desired torque (T).
AxT
The formula: C =B, ,
EXAMPLE
A bolt requires 30 foot-pounds and a 3 inch adapter (one-quarter of
a foot o r .251 is needed to get at it. You want to know what scale
reading it will take on a one-foot lever arm wrench to obtain the 30
foot-pounds at the bolt.
Remember. the 3 inch adapter must be projecting 3 inches straight
along the wrench axis. In general. avoid all complex assemblages or
adapters and extensions of flex joints.
20-01-00
Page 20-01
Revised: August 11. 1983
PIPER AIRCRAFT
P.4-32-301/301T
MAINTENANCE MANUAL
Am33
C
Lh
90"
-
1
A
T
F ~ g u r e20- I . Torque Wrench Formula
METHOD OF IXSTALLINC ROD END BEARINGS.
DAMAGE
HERE
e0'
DAMAGE
HERE
IMPROPER t00LIRESULTINO IN LOCKED BALL)
wnrmn MAV BE
WITH A L O W THROAT
-WLY CORRECT METHOD
Figure 20-2. Method of Installing Rod End Bearings
20-02-00
Page 20-02
Revised: August 11. 1983
PIPER AIRCRAFT
.
PA-32-301/301T
MAINTENANCE MANUAL
8361
SMALL
CENTER DRILL
Figure 20-3. Cherrylock Rivet Removal
CHERRYLOCK RIVETS, REMOVAL. (Refer to Figure 20-3.)
Should it be necessary t o remove an installed cherrylock rivet, the following procedures are
recommended:
I . In thick material remove the lock by driving out the rivet stem, using a tapered steel drift pin. (See
View I . )
Do not drill complete& through the rivet sleeve to remove a rivet as
this will rrnd to enlarge the hole.
2. If the rivets have been installed in thin sheets,drivingout the locked stem may damage the sheets. It is
recommended that a small center drill be used to provide a guide for a larger drill on top of the rivet stem. and
the tapered portion of the stem be drilled away to destroy the lock. (See View 2.)
3. Pry the remainder of the locking collar out of the rivet head with the drift pin. (See View 3.)
4. Drill nearly through the head of the rivet. using a drill the same size as the rivet shank. (See View 4.)
5. Break off rivet head, using a drift pin as a pry. (See View 5.)
6. Drive out the remaining shank with a pin having a diameter equal t o the rivet shank. (See View 6.)
20-03-00
Page 20-03
Revised: August 11, 1983
.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
IDENTlFlCATlOS 0 8 FLUID LINES. (Refer to Figure 204.)
Fluid lines in aircraft are often identified by markers made up of color codes, words. and geometric
symbols. These markers identify each line's function, content, and primary hazard, as well as the direction of
fluid flow.
In most instances, fluid lines are marked with 1 inch tape or decals. Paint is used on lines in engine
companments, where there is the possibility of tapes, decals or tags being drawn into the engine induction
system.
In addition to the above-mentioned markings, certain lines may be further identified as to specific
function within a system; for example. DRAIN, VENT, PRESSURE or RETURN.
Lines conveying fuel may be marked FLAM; lines containing toxic materials are marked TOXIC in place
of FLAM. Lines containing physically dangerous materials, such as oxygen. nitrogen. or freon. are marked
PHDAN.
The aircraft and engine manufacturers are responsible for the original installation of identification
markers, but the aviation mechanic is responsible for their replacement when it becomes necessary.
Generally. tapes and decals are placed on both ends of a line and at least once in each compartment
through which the line runs. In addition. identification markers are placed immediately adjacent to each valve.
regulator. filter or other accessory within a line. Where paint or tags are used, location requirements are the
same as for tapes and decals.
INSTALLATION OF FLEXIBLE HOSE ASSEMBLIES.
I. Flexible hose must not be twisted on installation.
Flexible hose which is installed with a twist may have a reduced service life and may cause a loosening of
the fittings to which it is attached.
2. Never exceed the minimum bend radius and avoid tight bends in flexible hose assemblies. (Refer to
AC43: 13-1. Chapter 10.)
3. Never stretch a hose tight between two fittings as this may result in overstressing and eventual failure.
The length of the hose should be sufficiently long to provide 5 to 8 percent slack.
FLARELESS TUBE ASSEMBLIES. (Refer to Figure 20-5.)
Although the use of flareless tube fittings eliminates all tube flaring, another operation, referred to as
presetting. is necessary prior to installation of a new flareless tube assembly which is performed as follows:
1. Cut the tube to correct length, with the ends perfectly square. Deburr the inside and outside of the
tube. Slip the nut, then the sleeve, over the tube (Step I).
2. Lubricate the threads of the fitting and nut. See Figure 2&5 for proper lubricant to use. depending on
the type system the tubing assembliesare t o be used on. Place the fitting in the vise (Step 2). and hold the tubing
firmly and squarely on the seat in the fitting. (Tube must bottom firmly in the fitting.) Tighten the nut until the
cutting edge of the sleeve grips the tube. This point is determined by slowly turning the tube back and forth
while tightening the nut. When the tube no longer turns, the nut is ready for final tightening.
3. Final tightening depends upon the tubing. For aluminum alloy tubing up to and including 1 : 2 inch
outside diameter. tighten the nut from one to one and one-sixth turns. For steel tubing and aluminum alloy
tubing over I , 2 outside diameter, tighten from one and one-sixth t o one and one half turns.
After presetting the sleeve, disconnect the tubing from the fitting and check the following points
(illustrated in Step 3):
I . The tube should extend 3/32 t o 118 inch beyond the sleeve pilot; otherwise blowoff may occur.
2. The sleeve pilot should contact the tube o r have a maximum clearance of 0.005 inch for aluminum
alloy tubing or 0.015 inch for steel tubing.
3. A slight collapse of the tube at the sleeve cut is
No movement of the sleeve pilot. except
rotation is permissible.
20-06-00
Page 20-04
Revised: August 11, 1983
PIPER A I R C R A m '
PA-32-3011301T
MAINTENANCE MANUAL
YELLOW NUMERALS. LEllERS.
AND STRIPE
1
SINGLE WIRE 1Rk0
YELLOW LEmRlNG
/
s m m c INNER TUBE
A. FLAME AND AROMATIC RESISTANT HOSE
I
I
I
8. NON-SELF-SEALING, AROMATIC
RESISTANT HOSE
I
(=m
I
(VIEWS SHOWING OPPOSITE SIDES OF HOSE)
C. NON-SELF-SEALING.AROMATIC AND
HEAT RESISTANT HOSE
1
RED NUMERALS. L m E R S AND STRIPE
I
I
1
0. SELF-SULING. AROMA1lC
RESISTANT HOSE
HOSE IDENTlFlUTION MARKING?
!
I
I
BROWN
ORANGE
ELECTRlCAL
CONDUIT
COMPRESSED
GAS
Dl
'Y(L
*"It
FUEL
BREATHING
OXYGEN
INSTRUMENT
AIR
HYDRAULIC
Vj?]
YEL,LOW
- h
,a#-
LUBRICATION
DEICING
17'1
BROWN
\
GRAY
/
8-
-0
10
..
e9'
a.
AIR
CONDITION
RED
FLUID UNE IDENTIFICATION USING TAPE AND DECALS
Figure 20-4. Hose/ Line Markings
20-06-00
P8#t 20 0 5
Reviwd: Aupst 11, 19113
PIPER AIRCRAFT
~ ~ - 3 2 - 3 0 1 / 3r
01
MAINTENANCE MANUAL
8363
TUBISG 9S'IEbt
HYDRAULIC
FUEL
OIL
PNEUMATIC
OXYGEN*
i
LUBRICA,XT
MIL-H-5606
MIL-H-5606
System Oil
MIL-L-4343
MIL-T-5542
* M I O N - D O NOT USE OIL OR GREASE
TUBING AND HOSE LUBRICANT'S
SLEEVE
FLARELESS-TUBE FITTING
U?TING EDGE
STEP 2
05 INCH MAXIMUM
-
ALWINUM
RESISTAN? STEEL TUBING
P&SFlTING FLARELESS-TUBE ASSPiBLY
Figure 20-5. Flareless Tube Fittings
20-06-00
Page 20-06
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
SUPPORT CLAMPS.
Support clamps are used to secure the various lines to the airframe or powerplant assemblies. Setera1
types of suppon clamps are used for this purpose. The rubber cushioned and plain are the most comrnonl!
used clamps. The rubber cushioned clamp is used to secure lines subject to vibration: the cushioning pretenrs
chafing of the tubing. The plain clamp is used to secure lines in areas not subject to vibration.
A teflon cushioned clamp is used in areas where the deteriorating effect of Skydroi 500. h>draulic flu~d
(MlL-0-5606)
or fuel is. expected. however. because it is less resilient. it does not pro1 ide as good a
vibration-damping effect as other cushion materials.
Use bonded clamps to secure hydraulic. fuel and oil lines in place. Unbonded clamps should be used only
for securing wiring. Remove any paint or anodizing from the portion of the tube at the bonding clamp
location. Make certain that clamps are of the correct size. Clamps or supporting clips smaller that the outside
diameter of the hose may restrict the flow of fluid through the hose.
All plumbing lines must be secured at specified intervals. The maximum distance between supports for
rigid fluid tubing is shown if Figure 20-6.
CHART 2001. HOSE C L A M P TIGHTENIKG (Ih'TIAL ISSTALLATIOS)
Clamps
Types
of Hose
Worm Screw Type
i
All Other Types
I
Finger-tight plus
two complete turns.
Self-sealing
Finger-tight plus
two and one half
complete turns.
,
I
!
I
I
Finger-tight plus
one and one quaner
complete turns.
All Other Hose
I
I
r
Finger-tight plus
two complete turns.
i
i
I
1
I f clamps do not seal at specified tightening, examine hose connection and replace parts
as necessap.
I
TUBE OD
(1 5.1
II
DISTANCE BETWEEN SUPPORTS ( IS )
ALUMINUM ALLOY
STEEL
Figure 20-6. Maximum Distance Between Supports for Fluid Tubing
20-07-00
Page 20-07
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
*MAINTENANCE MANUAL
EXTERIOR SURFACES.
The airplane should be washed with a mild soap and water. Harsh abrasives or detergents used on painted
or plastic surfaces could make scratches or cause corrosion of metal surfaces. Cover areas where clean~ng
solution could cause damage. To wash the airplane. the following procedure may be used:
I . Flush away loose din with water.
2. Apply cleaning solution with a rag. sponge or soft bristle brush.
3. To remove stubborn oil and grease. use a cloth dampened with naphtha.
4. Where exhaust stains exist. allow solution to remain on the surface longer.
5. Any good automotive wax may be used to preserve the painted surfaces. Soft cleaning cloths or a
chamois should be used to prevent scratches when cleaning or polishing. A heakier coating of wax on the
leading surfaces will reduce the abrasion problems in these areas.
WINDSHIELD AND WINDOWS.
I.
2.
straight
3.
Remove din. mud. etc.. from exterior surfaces with clean water.
Wash with mild soap and warm water. or an aircraft plastic cleaner usinga soft cloth or sponge and a
rubbing motion. Do not rub surfaces harshly.
Remove oil and grease with a cloth moistened with kerosene.
Do not use gasoline, alcohol, benzene, carbon tetrachloride,
thinner, acetone or window cleaning sprays.
4. After cleaning plastic surfaces. apply a thin coat of hard polishing wax. Rub lightly with a soft cloth.
Do not use a circular motion.
5. A severe scratch or mar in plastic can be removed by using jeweler's rouge to rub out the scratch.
Smooth both sides and apply wax.
6. To improve visibility through windshield and windows during flight through rain. a rain repellant
such as REPCON should be applied to the windshield and windows. The surfaces of the windshield and
windows treated becomes so smooth that water beads up and readily flows off the surface. Apply this product
in accordance with the manufacturerS instructions. (Refer to Chart 9105. List of Consumable Materials for
Specifications and Manufacturer's address.
HEADLINER, SIDE PANELS A N D SEATS.
1.
Clean headliner. side panels. and seats with a stiff brush and vacuum where necessary.
- CA UTION Solvent ckaners require adequate ventiktion.
2. Soiled upholstery. except leather. may be cleaned by using an approved air drying type cleaner or
foam u~holsterycleaner. Carefully follow the manufacturer's instructions. Avoid soaking or harsh rubbing.
3. ' ~ e a t h material
~r
should be cleaned with saddle soap or mild soap and water
20- 13-00
Page 20-08
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
'MAINTENANCE MANUAL
-
-
CARPETS.
Use a small whisk broom or vacuum to removedirt. For soiled spots. use a non-inflammable dq-cleaning
fluid.
ENGINE COMPARTMENT.
Before cleaning the engine compartment, place strips of tape on the magneto vents to prevent any solvent
from entering these units.
I . Place a pan under the engine to catch waste.
- CAUTION D o not gray solvent into the adremator, srartrr, vacuum pump, air
intake and akernate air inlets.
2. With the engine cowling removed. spray or brush the engine with solvent or a mixture of solvent and
degreaser. as desired. It may be necessary to brush areas that were sprayed where heavy grease and dirt
deposits have collected in order to clean them.
3. Allow the solvent to remain on the engine from five to ten minutes; then rinse the engine clean with
additional solvent and allow to dry.
-- C A UTION
-
D o not operate engine until excess solvent h a s evaporated or
otherwise been removed.
Remove the protective covers from the magnetos.
5. Lubricate controls. bearing surfaces. etc.. per Lubrication Charts. (Refer to Chapter 12.)
4.
FUEL QYSTEM.
1. T o flush the fuel tanks and selector valve, disconnect the fuel line at the injector.
2. Select a fuel tank, turn on the electric fuel pump and flush fuel through the system until it' is
determined then is no din and foreign matter in the fuel valve or tank. During this operation, agitation of the
fuel within the tank will help pick up and remove any dirt.
3. Repeat this procedure for each tank.
4. When all tanks are flushed, clean all filters.
20- 16-00
Page 20-09
Revised: August 11,1983
PIPER AIRCRAFT
PA-32-301 / 301 T
MAINTENANCE MANUAL
LANDING GEAR.
Before cleaning the landing gear. place a plastic cover or similar material over the wheel and brake
assembly.
I . Place a pan under the gear to catch waste.
2. Spray or brush the gear area with solvent or a mixture of solvent and degreaser. as desired. I t may be
necessary to brush areas that were sprayed where heavy grease and dirt deposits have collected in order to clean
them.
3. Allow the solvent to remain on the gear from five to ten minutes: then rinse the gear with additional
solvent and allow to dry.
4. Remove the cover from the wheel and remove the catch pan.
5 . Lubricate the gear per Lubrication Chart. (Refer to Chapter 12.)
-- END
-
20- 17-00
Page 20-10
Revised: August 11, 1983
CHAPTER
ENVIRONMENTAL SYSTEM
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 21 ENVIRONMENTAL SYSTEM
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
2 1-00-00
GENERAL
2 1 - 20-00
21-21-00
21-21-01
21-21-02
2 1-2 1-03
21-21-04
21-21-05
DISTRIBUTION
Cabin Vent System
Optional Overhead vent Blower Description
Removal of Blower Assembly
Disassembl!l of Blower Assembly
Reassembly of Blower Assembly
lnsiallation of Blouer Assembly
2 1-40-00
21-41-00
2 1-32-00
HEATISG
Description and Operation
Heater Maintenance
GRID
KO.
EFFECTIF'ITY
COOLING
Description and Operation
Troubleshooting
Malfunction Detection
Special Senicing Procedures
Ser\.ice Val\ es
S e n ice Valve Replacement
Test Gauge and Manifold Set
Checking the System for Leaks
Leak Check - Method 1
Leak Check - Method 11
Discharging
E\acuating the System
Charging the System
Charging Stand Method
Airplane Compressor Method
Addition of Partial Charge to System
Component Service
Compressor Service
Compressor Removal
Compressor Installation
Checking Compressor Oil
Replacement of Compressor Drive Belt
-
- ).
21 Cont./Effec.
Page 1
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
-
CHAPTER 21 ENVIRONMENTAL SYSTEM (cont)
TABLE OF CONTENTSIEFFECTIVITY
CHAPTER
SECTION
SUBJECT
SUBJECT
COOLING (cont)
Component Service
Adjustment of Drive Belt Tension
Magnetic Clutch
Magnetic Clutch Removal
Magnetic Clutch lnstallation
Refrigerant Lines and Routing
Receiver-Dehydrator
Removal of Receiver-Dehydrator
lnstallation of Receiver-Dehydrator
Condenser
Removal of Condenser
lnstallation of Condenser
Condenser Door Actuator
Condenser Assembly Rigging Instructions
Expansion Valve
Removal of Expansion Valve
lnstallation of Expansion Valve
Evaporator
Removal of Evaporator
lnstallation of Evaporator
Pressure Relief Switch - Ranco
Electrical lnstallation
Adjustment of Throttle Switch
Fuse Replacement
GRID
SO.
IF19
l F2O
l F2O
l F2l
l F2l
l F22
I F22
I F22
l F22
I F22
I F2?
I F23
I F23
1G1
IGI
IGI
1G2
IG2
IG2
1G6
IG6
I G6
I G6
EFFECTIVITY
l R 8-83
IR
lR
IR
IR
IR
lR
-
8-83
8-83
8-83
8-83
8-83
8-83
21 Cont./Effec.
-
Page 2
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /30lV.'
MAINTENANCE MANUAL
GENERAL.
This chapter contains instructions for operating. senicing. inspection and repair of the EnLironmental
System components installed in this airplane.
DISTRIBUTION.
I
CABIN VENT SYSTEM. (Not Available With Air Conditioning.)
The overhead vent system utilizes thesameductingas that of theairconditioningsystem. (Refer to Figure
21-1 or 21-2.) Air enters a n inlet located on the left side of the rear fuselage and is ducted through the Lent
system. Airflow is controlled by a flapper valve positioned in the duct just forward of F.S. 220. The "CAB1 S
Al R" control knob. located in the cockpit overhead duct. positions the flapper valve t o allow fresh air to enter
the cabin o r t o stop the flow of air. This vent system may also be equipped with a blower (optional). This
blower. mounted aft of the close-out panel underneath the top of the fuselage. will force air through the
overhead vent system whenever desired.
1
I
OPTIONAL OVERHEAD VENT BLOWER DESCRIPTION.
~i
T h e blower is mounted in the aft section of the fuselage and is connected to the overhead vent s!.stem. The
blower draws air in from the left rear side of the fuselage and forces it through the ducting. w h e n e ~ e rdesired.
(The three position blower switch on the instrument panel controls the two speed blower.)
I
REMOVAL O F BLOWER ASSEMBLY.
I
I
I . Remove the access door from the aft wall of the baggage area.
2. With the master switch off. disconnect the plug assemblies at the blower assembl).
3 . Remobe the inlet and outlet hoses from the blower assembly by removing the clamps.
4. Remove the screws. washers and nuts that secure the blower assembly to the hanger braces.
5 . Remove the screws and washers which secure the blower assembly t o the retainer and hangers.
6. Remove the blower assembly from the aircraft.
DISASSEMBLY OF BLOWER ASSEMBLY.
I . RemoLe the hose duct from the forward edge of the blower assembly by removing the nuts. as hers
and screws.
2. Remove the cover from the blower assembly by removing the nuts. washers and screws.
3. Remove the blower fan from the motor shaft by removing the set screw.
4. For removal of the motor. proceed a s follows:
A. Separate the plate from the motor cover by carefully drilling out the connecting ritets.
8. Cut the motor wires a t the edge of the receptacle and plug and remove the wire ends from the
blocks.
C. Remove the motor from the mounting plate by removing the nuts. washers and bolts.
21-21-03
Page 21-01
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
REASSE,MBLI' OF BLOWER ASSEMBLY.
I . Mount the motor on the plate and secure it with the bolts. washers and nuts. Be sure that the motor
nuts are snup and the shaft spins freel!..
1. Position the co\er o\.er the motor plate with the motor wires protruding through the co\.er grommet.
3. H'ith the holes in the cover matching the holes in the motor plate. secure the t u o parts together u i t h
rivets.
4. Apply PRC-5000 sealant t o fill any opening left after the wires are brought through the grommet.
5 . lnstall the wires in the plug and receptacle.
6. Position the blower fin o n the motor shaft and secure with set screw.
7. Secure the co\,er t o the blower assembly with screws. washers and nuts.
8. Position the hose duct o n the blower assembly and secure it with screws. washers and nuts. The screws
must be installed with their heads inside the duct.
9. After cleaning the surfaces of all old sealant. use white rubber chalk PRC-5000 sealant t o seal \\-here
the duct attaches t o the blower assembly.
INSTALLATIOIY OF BLOWER ASSEMBLY.
I.
Position the blower assembly in the hangers and retainer a n d install the washers and scre\\i.
2. Install the nuts. washers and screws securing the blower assembly t o the hanger braces.
3. Seal all hose joints with Arno No. C-520 wrap tape: then install the inlet and outlet hoses cecuring
them u i t h the clamps.
4. With the master switch off. connect the plug and receptacles at the blower.
5. Check the blower for the proper operation.
6 . Install the access d o o r t o the aft wall of the baggage area and secure with the attaching harduare.
I
C H A R T 2101. BLOWER SYSTEM WIRE C O L O R C O D E S
AIRCRAFT
WIRES
MOTOR WIRES
Y Y 1 SO62
Pin
Kos.
ESB - Universal
Elect. Company
Aircraft
Harness
Pin
30s.
Ground
Plug
2
Brown
AC26A
2
Receptacle
Low Speed
Plug
I
Yellow
Black
I
Receptacle
H ~ g hSpeed
Receptacle
I
Orange
Red
I
Plug
L
- NOTE Pin number 1 I at the pointed side of the plug and receptacle.
21-21-05
Page 11-02
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32.301 /301T
MAINTENANCE MANUAL
HEATISG.
DESCRIPTIOS A S D OPERATIOS.
The heating slstem is designed tosupply warm air t o the cabin during u i n t e r a n d cool ueather flights. 1-he
s!stem ~ncludesa heat shroud. heat ducts. defroster outlets. heat a n d defroster controls.
-- CA UTION
-
When cabin heat is operated heat duct surface becomes hot. This
could result in burns if arms or legs are placed too close to heat duct
outlets or surface.
Fresh air is ducted from the left engine baffle t o the heater muff which is attached to the muifler. The
heited air is then ducted to the valve box mounted o n the fire wall. When the valle is open. heated alr enter, thc
heat ducts located along each side of the center console. Outlets in the heat ducts are located at each \cat
location. Airflou to the rear seats can be regulated by controls in the heat ducts located betheen the front seat\.
The temperature of the cabin is regulated by the heater control located on the right side ot'thc in,trtimc.nt
panel.
Defrosting is accomplished by heat outlets located on the right and left side of t h e c o u l c o \ e r . Heated air is
ducted directl!. trom the heater v a k e box t o the defroster shutoff lalves at the fire wall and then to the det'roster
outlets. The airflow is regulated by a defroster control located below the heat control.
T o aid air distribution. the cabin air is exhausted overboard by a n outlet located on the bottom 01 the
fuselage. Cabin exhaust outlets are located below and aft of the rear seats.
HEATER MAINTENANCE.
I f the exhaust manifold should become defective. carbon monoxide fumes ma!. be discharged Into the
cabin area. therefore it is imperatile that the exhaust manifold be inspected regularl!. Refer to Chapter 71; lor
inspection of exhaust systems. The heater muff must be remobed in order t o inspect the manifold as,embl!.
Check the operation of the push-pull controls to insure the valve doors function properl!,. \\hen the control\
are pulled out. the door should be completely open t o permit full airflow. \{'hen the controls are pushed in. the
l.al\es should close off all air passage and vent the air into the engine compartment. Refer ro F ~ g u r e2 1 - 1 or
2 1-2 for an illustration of the heater system.
21-42-00
Page 21-03
Revised: August 1 1 , 1983
PIPER AIRCRAFT
PA-32-301 / 3 0 1 ~
,MAINTENANCE MANUAL
2
/'
/
I
I
1
I
I
I
i
I
9
.
.
1 . HEAT SHROUD
2. DEFROSTER VALVE
3. DEFROSTER ounn
.
4. HEAT AND DEFROSTER AIR CONTROLS
5. OVERHEAD FRESH AIR DUCT
6. FRESH AIR o m n
7. OVERHEAD VENT BLOWER
8 . FRESH AIR INLET
9. AIR BOX
10. CABlN HEAT OUTLET
1 1. CABIN AIR EXHAUST
12. DRAIN TUBE
13. FRESH AIR FLAPPER VALVE
Figure 21 - I . Cabin Heater. Defrosters and Fresh Air System (PA-32-301)
21-42-00
Page 21-04
Revised: August l I . 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
-
---.
i
1. HEAT SHROUD
2. DEFROSTER VALVE
3 DEFROSTER OUTLET
4 HEAT AND DEFROSTER AIR CONTROLS
5. OVERHEAD FRESH AIR DUCT
6. FRESH U R OUTLET
7 OVERHEAD VENT BLOWER
8. FRESH AIR l N L n
8. AIR BOX
10. WIN HEAT OVNI
1 1. CABIN AIR MHAUST
12. OMlN No€
13. FRESH AIR FLAPPER VALVE
,
Figure 21-2. Cabin Heater, Defroster and Fresh Air System (PA-32-MIT)
21-42-00
Page 21-05
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
DESCRIPTIOS ASD OPERATIOK.
This installation consists of a compressor with its special bracketry. an evaporator. a condenser. L\
recei~er-deh!.drator. circulating fan. thermal expansion valve. and related plumbing.
The ekaporator filters. dehumidifies and cools the air. The evaporator is mounted in a fabricated housing
along with the receiver-dehydrator. circulating fan. thermal expansion valve and related plumbing. Thi3
housing is located at the rear of the cabin. aft of the baggage area. The compressor is a two cylinder. piston t! pe
compressor u hich is supported by special bracketry at the front of the engine. A V-belt connected to the engine
ring gear dri1.e~
the compressor through a magneticclutch. Thecondenser is installed on a hinge mounted door
that is located on the bottom portion of the fuselage tail section. Thecondenser door is hinge mounted to allon
extension into the airstream during system operation. The condenser door is electricall> actiiated to pro\ idct
the following positions (system on - fully extended or system off - fully retracted).
The system is protected by a Ranco type pressure switch which automatically controls the condenser
maximum head pressure by temporarily de-clutching the compressor in the event the pressure become,
excessi\el! high. The controls are located on the aircraft instrument panel adjacent to the heater and defrohter
le\.ers. and consist of air conditioning control. a fan control to govern the cold air velocit!.. and a trmperarurct
control.
The s!.stem is such that there is no increase in drag to the aircraft during its take-off flight condit~on,.
During maximum pou.er demands the compressor is de-clutched and the condenser door is automaticall!
retracted.
The air conditioning system in this aircraft is a recirculating. independent unit. I t filters. dehumidific\ and
cools the air as it c!.cles through the evaporator. The unit is operated from controls mounted on the right side
of the instrument panel. The air conditioning master switch has two positions. OX-OFF. N'hen the ".A1 R
C O S D " position is selected the compressor clutch engages. the condenser scoop opens and the circulating I'an
is turned on. The temperature is controlled by a thermostat operated by the temperature control selector. I
t ~ position
o
fan switch (LOW-HIGH) operates the blower. The fan may be operated to circulate air ~ i t h o u t
using the air conditioning unit.
The air conditioning system uses Refrigerant I2 as the refrigerant. The refrigerant enters the compressor
as a t a p o r . The compressor pressurizes the heat-laden vapor until its pressure and heat reach a point much
hotter than the outside air. The compressor then pumps the vapor to thecondenser where it cools and change\
to a liquid. The liquid then passes to the receiver-dehydrator. Its function is to filter. remoIe an) moisture and
insure a steady flow of liquid refrigerant into the evaporator through the expansion valve. Theexpan3ion \ a l l ct
is a temperature controlled metering valve which regulates the flow of the liquid refrigerant to the ei.aporator.
The e ~ a p o r a t o absorbs
r
the heat from the air passing over thecoils. From the evaporator the refrigerant iapor
returns to the co'mpressor where the cycle is repeated.
I
~
I
,
I
The air conditioning system should be operated at least once a
month to prevent sticking valves and keep the system lubricated.
,
TROUBLESHOOTING.
Probable troubles peculiar to the air conditioner system components covered in this chapter are listed in
Chart 2 101. along with their probable causes and suggested remedies. After the trouble has been corrected.
check the entire system for security and operation of its components.
21-52-00
Page 21-06
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1.101 T
MAINTENANCE MANUAL
CHART 2102. TROUBLESHOOTING (AIR CONDITIONER)
Gauge Indication
High discharge pressure.
Low discharge pressure.
Low suction pressure.
Accompanied by icing
evaporator.
Probable Causes
Remedy
Overcharge of refrigerant.
Purge excess refrigerant.
Air in system.
Check for leaks. Bleed
charge from system.
Evacuate and recharge
system.
Overheated condenser due
t o blocking air passage.
Clean bugs and dirt
from condenser fins.
Straighten fins if
bent.
Flooded evaporator indicated by heavy frosting
on suction line and compressor suction service
valve.
Check that capillary bulb
is securely clamped to
suction line. If capillary bulb OK replace
expansion valve.
Restriction in liquid line
from condenser.
Check for kinked hoses and
stopped up filter.
Undercharge of refrigerant. Sight glass shows
bubbles or foam.
Add refrigerant until
bubbles disappear. Check
system leaks.
Damaged compressor valves
or d i n under valves.
Replace compressor.
Damaged compressor. Worn
or broken piston or
piston rings.
Replace compressor.
Low air supply through
evaporator.
Repair blower or blower
motor. Clean stoppage in
air ducts.
Very diny evaporator
fins and coils.
Clean and flush with
water.
Page 21-07
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
C H A R T 2102. TROUBLESHOOTING (AIR CONDITIONER) (cont)
-
Gauge Indication
Low suction pressure.
(Evaporator not cold
enough) Suction gauge may
read a vacuum indicating
evaporator lacks refrigerant .
High suction pressure.
Probable Causes
Undercharge of refrigerant.
Moisture freezing in expansion valve. Valve will show
frost. Expansion valve inlet
screen clogged. Inoperative
expansion valve. Valve stuck
closed or capillary bulb has
lost its charge.
-
Remedy
Add refrigerant. Install new
dryer. Evacuate and recharge.
Remove screen. Clean with
solvent and replace. Warm
capillary by holding in hand.
If suction pressure does not
charge, replace expansion
valve.
Restriction anywhere in
liquid line. Restriction will
show frost.
Locate restriction and repair.
Capillary bulb clamp loose
on suction line. Suction line
shows frost.
Clean contact surfaces of
suction line and cap bulb.
Tighten clamp.
Expansion valve not closing.
Evaporator flooded. Suction
line frosted to compressor.
Replace expansion valve.
Compressor drive belt
slipping.
Adjust belt tension.
Magnetic clutch slipping.
Check electrical circuit for
correct voltage to clutch coil.
Clean clutch surfaces of oil.
Leaking or broken compressor valves.
Replace compressor
Page 21-08
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
a
CHART 2 103. TROUBLESHOOTING (AIR CONDITIONING SYSTEM)
Trouble
Cause
Condenser door will not
close when air conditioner
switch is in the "OFF*
position.
Faulty relay 'K-2".
System produces no
cooling.
Electrical
Remedy
Replace relay.
Blown fuse in control
head.
Replace fuse.
Open circuit breaker.
Reset circuit breaker.
Broken or disconnected
electrical wire.
Check all terminals for
loose connections; check
wiring for hidden
breaks.
Broken or disconnected
ground viire.
Check ground wire to see
if loose, broken, or disconnected.
Clutch coil burned out or
disconnected.
Check current flow to
clutch, replace if
inoperative.
Thermostat sensing element
defective.
Check thermostat and cabin
comfort control panel.
Blower motor disconnected
or burned out.
Check current flow to
blower motor. Repair or
replace if inoperative. .
Mechanical
Loose or broken drive belt.
Replace drive belts
a n d / o r tighten to
specifications.
Compressor partially or
completely frozen.
Remove compressor for
service or replacement.
Expansion valve stuck in
open position.
Replace expansion valve.
Page 21-09
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 2103. TROUBLESHOOTING (AIR CONDITIONING SYSTEM)(cont)
Trouble
System produces no
cooling. (cont)
.
Cause
Refrigeration
Broken refrigerant line.
Examine all lines for
evidence of breakage by
external stress or rubbing
wear.
Leak in system.
Evacuate system, apply
static charge, leak test
system, and repair leak as
necessary.
Compressor shaft seal
leaking.
Replace compressor.
Clogged screen or screens
in receiver dehydrator or
expansion valve; plugged
hose or coil.
System will not produce
sufficient cooling.
Remedy
.
Repair a s necessary
Electrical
Blower motor sluggish in
operation.
Remove blower motor for
service or replacement.
Mechanical
Compressor clutch slipping.
Remove clutch assembly for
service or replacement.
Obstructed blower passage.
Examine entire passage for
.
obstruction. Correct as
necessary.
Insufficient air circulation over condenser
coils; fins clogged with
d i n or bugs.
Clean condenser coils
Evaporator filter clogged.
Clean with cleaning
solvent to remove
cigarette tars.
21-52-00
Page 21-10
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
M-QINTENANCE MANUAL
C H A R T 2103. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont)
Trouble
System will not produce
sufficient cooling. (cont)
Excessively noisy system.
Cause
Remedy
Refrigeration
Insufficient refrigerant in
system.
Recharge system until bubbles disappear in receiver
dehydrator and gauge readings stabilize to specdications.
Clogged screen in expansion valve.
Purge system and replace
expansion valve.
Expansion valve thermal
bulb has lost charge.
Purge system; replace expansion valve.
Clogged screen in receiver
dehydrator.
Purge system; replace receiver dehydrator.
Excessive moisture in
system.
Purge system; replace receiver dehydrator.
Air in system.
Purge, evacuate and charge
system. (Replace receiver
dehydrator)
Electrical
Defective winding or improper connection in compressor clutch coil.
Replace or repair as necessary.
Mechanical
Loose or excessively worn
drive belts.
Tighten or replace as required.
Noisy clutch.
Remove clutch for service
or replacement as necessary.
Page 21-11
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE MANUAL
C H A R T 2103. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont)
Trouble
Excessively noisy system.
(cont)
Cause
Remedy
Electrical (cont)
Compressor noisy.
Check mountings and
repair; remove compressor
for service o r replacement.
Compressor oil level low.
Fill with correct amount
of specified oil.
Refrigera tion
Excessive charge in system.
Discharge excess freon
until high pressure gauge
drops within specifications.
Low charge in system.
Check system for leaks:
charge system.
Page 21-12
Revised: August 11, 1983
PIPER AIRCRAFT
F'A-32-301/301 T
J1.AISTES.ASCE \I.ASI'AL
1 COMPRESSOR
2 FREON LINES
3 ALTERNATOR
4 PULLEY POSITIONS
5 DUCT ASSEMBLY
6 EVAPORATOR FILTER AND COVER
7 EXPANSION VALVE
8 PRESSURE SWITCH
9 RECEIVER-DEHYDRATOR
10 EVAPORATOR
1 1 BLOWER MOTOR
1 2 CONDENSER
13 COVER ASSEMBLY
14 BELLCRANK ASSEMBLY
-
COMPRESSOR AND
ALTEINATOR AS S'Y - [SEE SKETCH A1 / -
__
-
--
b
i
-
c-1-- --*
\-7-
-__--
--
-
FIEOH LINES
-
CONOENStR
ISLE SKETCH CI
-- -
EVAPORATOR AND DUCT
!SEE SKETCH )I
<
7
-
\
I
--
i-I
/
/-
-- / -.
21-52-00
Page 21-13
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
~p
MALFCNCTIOX DETECTION.
I
The detection of system malfunction largely depends on the mechanic's ability to interpret the gauge
pressure readings into system problems. A system operating normally will have a low side gauge pressure
reading that will correspond with the temperature of the refrigerant evaporating in the evaporator. allowing
for a few degrees temperature rise due t o loss in the tube walls and fins. The high side will have a gauge pressure
that will correspond with the temperature of the refrigerant condensing in the condenser. allowing for a few
degrees temperature drop due to loss in the tube walls and fins.
Any deviation from that which is normalindicatesa malfunction within the system due to a faulty control
device, obstruction. defective part, or improper installation.
Detection of system malfunction is made easier with the knowledge that the temperature and pressure of
Refrigerant 12 is in close proximity between the pressures of twenty and eighty pounds per square inch (psi).A
glance a t the Temperature-Pressure Chart 2104 will show that there is only a slight variation between the
temperature and pressure of the refrigerant in the lower range.
I t is correct to assume that for every pound of pressure added to the low side. a temperature increase of
about one degree Fahrenheit takes place. For instance. a pressure of 23.8 on the chart indicates a temperature
of 24°F. A change of pressure of almost one pound to 24.6 psi gives us a temperature increase to 25°F.
- NOTE For each 1,000 feet of elevation above sea level, the gauge readings
will be about one inch of mercury or l / 2 psi higher than the chart
indicates.
It must be pointed out that the actual temperature of the air passing over thecoils of the et,aporator u ill be
several degrees warmer allowing for a temperature rise caused by the loss in the fins and tubing of the
evaporator.
The importance of a seasonal check up of the air conditioning system should be brought t o the attention
of the customer whenever possible. A thorough check of the system performed in a methodical manner will
reveal trouble the customer is often not aware of. Locating and repairing the troubleearly will usually result in
savings t o the customer both in time and additional troubles that too often result from neglect.
A Performance Test of the system is the only positive way in which the complete system can be checked for
efficient operation. The air conditioning system should be given this test before work is begun on the system
whenever possible. however, if the system is completely inoperative. repairs must be performed before the
system can be properly tested. The test can uncover further work that must be performed before the system is
brought t o its full operating efficiency. The Performance Test should always be performed after repair work
has been done and before the aircraft is released t o the customer. The serviceman performing this test carefully
will insure that the repairs have been properly performed and that the system will operate satisfactorily.
The Performance Test when properly performed includes a thorough examination of the outside of the
system as well as the inside. Many related parts are overlooked because it is felt they are of no bearing on the
operating efficiency of the unit. For this reason. a thorough visual inspection of the complete system should be
performed. followed by an operating inspection of the system.
21-52-01
Page 21-14
Revised: August II. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CH A R T 2101. T E M P E R A T L ' R E P R E S S I ' R E
E ~ a p o r a r o rPressure
Gauge Read~ng
p s I.
0
24
4.5
10 1
II 2
11.3
13 4
14 6
15 8
17 1
18 3
19 7
21
22 4
23 I
23 8
24 6
25 3
96 1
26 1
27.6
25 4
29 2
30
30 9
!I '
32 5
33
34 3
35 1
36
36 9
3' 9
78 5
39 7
41 7
4.1 h
45 6
48 7
49.8
55 4
60
64 9
Ebaporator
Temperature
OF.
-2 1
- 15
- 10
2
4
6
8
10
I2
14
16
18
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
45
47
49
52
53
57
62
66
High Pressure
Gauge Reading
p.s.i.
Amb~ent
Temperature
O F.
72
86
105
109
113
117
122
126
1 29
132
134
137
140
144
148
152
156
160
162
165
167
170
172
175
177
180
182
185
187
189
191
193
195
200
205
210
2 15
220
228
236
260
275
290
40
50
60
62
64
66
68
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
102
104
110
115
120
21-22-01
Page 21-12
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-3011 3 0 1 . ~
MAINTENANCE MANUAL
SPECIAL SERVICING PROCEDURES.
The air conditioning system should be serviced by a qualified shop with trained personnel. The f o l l o ing
~
procedures and precautions should be observed.
The efficiency of this system depends upon the pressure-temperature relationship of pure refrigerant. A S
long as the system contains only pure refrigerant plus a specified amount of compressor oil ( ~ . h i c his mixed
with the refrigerant). it is considered to be chemically stable. Foreign materials within the system will affect the
chemical stability. contaminate the system. and decrease its efficiency.
I. G E K E R A L REFRIGERATlOh' SYSTEM PROCEDURES.
A. REFRIGERANT SAFETY PRECAUTIOKS.
( I ) Refrigerant 12 (commonly known as R-12 o r "Freon" 12) is odorless and colorless in either
the liquid or gaseous state. R-12 for charging refrigeration systems is supplied in
pressurized containers (approx. 70 psi a t 70°F in liquid form. Since this material is
essentially inert at room temperatures the dangers are primarily associated with the
pressure and the refrigeration effects of the release and subsequent evaporation of t h ~ s
pressurized liquid.
( 2 ) \'ear suitable eye protection when handling R-12 due to the possibility of freezing of the
eye if contacted by escaping liquid refrigerant. If liquid R-12 does strike the e!e. the
follow,ing actions should be taken:
( a ) DO S O T R C B T H E EYE.
( b ) Splash large quantities of cool water into the eye to raise the temperature.
(c) Tape on a n eye patch to avoid the possibility of dirt entering the e!,e.
( d ) Rush to a physician or hospital for immediate professional aid.
(e) DO Y O T A T T E M P T T O T R E A T I F YOURSELF.
(3) I f liquid R-I2 strikes the skin frostbite can occur. Treat with cool water and protect u ~ t h
petroleum jell!..
(4) D o not discharge large quantities of R-I2into closed rooms. It may displace most of the air
in the room and this could cause oxygen stanation. Gaseous R-12 is heairier than air and
flous to the bottom of a container.
( 5 ) D o not discharge R-12 into a n open flame o r onto a very hot surface (50OCF+).Poisonous
phosgene gas is generated by the action of the heat on the refrigerant.
( 6 ) D o not appl!. direct flame or other high heat source to a R-I2 container due to the h ~ g h
pressures w.hich will result. If any heating is done to R-12containers the container pressure
should be monitored and kept below 150 psi.
B. SYSTEM SERVICING PRECAUTIONS.
S!.stems should be discharged slowly to prevent the escape of liquid refrigerant and the loss
( 1)
of the lubrication oil.
S!stems should not be left open t o the atmosphere when discharged. Moisture and other
2
contamination may enter and damage open systems.
(1) Ke\er introduce anything but pure refrigerant and refrigerant oil into a system.
(4) Keep refrigerant oil containers tightly sealed and clean to prevent absorption of moisture
or other contamination.
5
Use only appro\ed refrigeration oil in the compressor. If any doubt exists about the
cleanliness of the compressor oil. replace it with new oil.
( 6 ) Ne\er reuse oil removed from the system. Discard it.
( 7 ) H'hen Loctite Refrigerant Sealant has been used on a joint it must be heated to 400' F p r ~ o r
to disassembl!.. Loctite must be used to seal any pipe threads in the system lines.
Page 21-16
Revised: August l I. 1983
PIPER AIRCRAFT
PA-32301/301T
MAINTENANCE MANUAL
t61
Replace the receiver-dehydrator assembly o n any system which has been operating u i t h a
leak aIlouing air t o enter the system. If a receiverdehydrator is left open to theatmosphere
it should be replaced due t o the loss of effectiveness of the drying compound it contains.
- NOTE A very strong acid (HCL) is formed when R-I2comes in contact
with moisture.
A neu receiver-dehydrator should be opened and connected to the system only n hen read!
t o charge the system with refrigerant.
(9) Recommended torque values must be used o n all flare fitting a n d O-ring joints. See Chart
2105
CH 4 R T 2105. ALL'MIYCM TL'BISG TORQC'E
I
3letai Tube
0 D.
1 3
3 5
1 2
5 P
3 1
Thread and Fitting
Size
7
5
3
7
16
8
4
8
1 - 1 16
Alum. T u b ~ n g
Torque
5-7 ft.-lbs
11-13 ft.-lbs
15-20 ft.-lbs
2 1-27 ft.-lbs.
28-33 ft.-lbs.
The purpose of the s e n i c e \ a l \ e is t o ser\.ice the air conditioning system. (Testing. Bleeding. E\acuaring
and Charging). This aircraft is equipped u i t h ser\.ice valves mounted in the suction and discharge lines o i thc
e \ a p o r a t o r assembl!. These \ a l \ e s are the "2" position type Schrader val\.es. All normal alr conditioning
s e n i c e should be periormed a t the eiaporator assembly mounted vakes.
Service valves are also located on the compressor. However, use of
these vah-es in servicing is not recommended.
If a Schrader service valve is not serviceable, the core assemb!v must
be replaced.
2 1-53-0I
Page 21-17
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
COMPRESSOR VALVE
(SCHRADER CHARGING)
I N L I N E SERVICE VALVE (SCHRADER)
Figure 2 1-4. Service Valves
SERVICE VALVE REPLACEMENT.
The valves on the compressor are sealed with a gasket placed in the valve port boss. Lubricate the gasket
with refrigerant oil of the type used in the compressor. place the valves with the tube fitting facing aft and
secure with . 3 12 bolts. torque to 15-23 inch-pounds.
Whenever the air conditioning rdrigerant lines or system is opened
for any reason, the lines and fittings should be capped and sealed
immediate@ to prevent dirt and other conturninants from entering
the system. (It is not advisable to put a plug into the hoses or
fittings.)
Page 21-18
Revised: August 11, I983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
408
COMPOUND
HIGH PRESSURE
PRESSURE GAGE
GAGE
TO DISCHARGE
SEYVICE VALVE
SERVICE VALVE
TO VACUUM PUMP OR
REFRIGERANT CYLINDER
Figure 21-5. Test Gauge and Manifold Set
TEST GAUGE ASD MANlFOLD SET.
The proper testing and diagnosis of the air conditioning system require that a manifold gauge set be
attached into the system. This set consists of two gauges mounted to a manifold. One gauge is a high pressure
gauge used in the discharge side of the system. The other is a low pressure gauge used in the suction side of the
system. The manlfold is a de\,ice ha\.ing fittings for both gauges and connection hoses with provisions for
controlling the flow of refrigerant through the manifold. (See Figures 21-5 and 21-6.)
The center port of the manifold set is used for charging or evacuation procedures. or any other ser\.ice that
may be necessary.
Both the high and IOU side of the manifold have hand shut-off valves. When the hand valve is turned all
the way in. in a clockwise direction. the manifold is closed. The pressures on that side of the s!.stem ill.
h o ~ , e \ e rbe
. recorded on the gauge above the hose.
Cracking the hand valie. in the counterclockwise direction. opens the system to the middle service port of
the manifold set. T h ~ sis desirable only when it is necessary to let refrigerant out o r into the system. Refer to
F ~ g u r e s2 1-5 or 2 1-6.
CHECKING T H E SYSTEM FOR LEAKS.
There are several methods of doing this operation. depending on the type of equipment which is available.
Tu,o methods of performing this check will be covered in the following paragraphs.
21-21-00
Page 21-19
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
7267
DIAGRAM A
DIAGRAM B
DIAGRAM C
DIAGRAM D
Figure 2 1-6. Manifold Set Operation
Page 21-20
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-30113011'
MAINTENANCE MANUAL
b
0.0
COMPOUND
GAGE 50 P . S .
R E S S U R E GAGE
SCHRADER VALVE
SCHRADER V A L V E
REFRIGERAKT
CONTAINER
OPEN T O 50 P . S . I .
THEN CLOSE
EVAPORATOR A S S ' Y
Figure 21-7. Leak Test Hookup
-NOTE
-
Evacuate system prior to leak check.
LEAK CHECK
- METHOD I.
1 . Connect the manifold gauge set into the system and determineif there isany refrigerant in the system.
A minimum of 50 psi refrigerant pressure in the system is needed for leak detection. (Refer to Figure 2 1-7.)
2. Purge the hoses of air by allowing some refrigerant to escape from the connections at the senice
valves. Then tighten connections at the service valve.
3. Close the low side manifold valve and open the high side manifold valve.
4 . Open the refrigerant container service valve and allow the pressure at the low side gauge to reach 50
psi at which time close the high side manifold valve.
5. Close the refrigerant container service valve and remove the hose if no leaks are evident.
6. I t is advisable to use an electronic leak detector to check this system instead of an open flame leak
detector due to the possible presence of gasoline fumes in the engine area.
7. If any leaks are found, purge the system of refrigerant, make the necessary repairs and check the
compressor oil.
8. Add oil. if required, (refer to Checking Compressor Oil and Chart 2107) then repeat Steps 1 thru 5.
9. If no further leaks are found, the system may be evacuated and charged. (Refer to Evacuating the
System and Charging the System.)
21-54-01
Page 21-21
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
LEAK CHECK
- METHOD 11.
1. Remo\e the access panel at the rear of the cabin to gain access t o the service valves.
2. Remo\ e the protective cap on the high pressure Schrader valve fitting and connect a charging hose
with a shut-off valve arrangement to the fitting. The charging hose must have a Schrader fitting or adapter 15
fit the 1,albe.
3. Connect the other end of the charging hose t o a small cylinder of refrigerant and purge the hose hk
allouing a slight amount of refrigerant gas t o escape from the Schrader valve fitting.
4. The cylinder of refrigerant should be placed upright in a container of warm (125°F max.) water on a
small scale.
5. Allow approximately 1 ' 2 pound of refrigerant to enter the system by opening the valve on the
charging hose and obsening the weight change on the scale.
6. Using an electronic leak detector, check all joints and repair any leaks.
7. After complet~onof repair of any leaks, proceed to check the system in accordance with one of the
methods outlined for an! other leaks.
8. If n o further repair is required on the system. it is now ready t o evacuate in accordance ~ i t h
Ekacuating the System.
DISCHARCISG. (Required only if system contains refrigerant.)
-- NOTE
-
Applies to Kent Moore 523500 or similar charging station. (Refer to
Figure 21 9.)
-
1'
1. Close all \.alves on charging station.
2. Connect red high pressure chargng line to high pressure Schrader valve at the evaporator fitting.
3. Open high pressure control valve on charging station one turn.
4 . Hold end of blue low pressure charging line in a shop rap and slowly open loul pressure control val\ e
on charging station allouing refrigerant to exhaust from system into shop rag.
- CAUTION Refrigerant can causefreezing of skin. Be particularly carefulnot to
allow contact with the eyes.
Do not allow refrigerant to escape too rapidly, as excessive oil may
be carried out of system. When hissing stops, system is empty and
valve should be closed ij no further work is planned.
Page 21-22
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 130 1T
MAINTENANCE MANUAL
*I8
COMPOUND GAGE
P U L L 26 TO 28
INCHES VACUUM
PRESSURE GAGE
SCHRADER VALVE
SCHRADER
VALVE
VACUUM PUMP
N3TE
OPEN BOTH SERVICE VALVES
EVAPORATOR ASS'Y
(COUNTERCLOCKWISE) ONE TURN
Figure 2 1-8. Evacuation Hookup
E \ ' A C L A T I S G THE Sl'STE3Z.
If the system has been operated in a discharged condition o r anytime the system has been open t o
atmospheric pressure. the receker-dehydrator must be replaced and the system evacuated t o remo\.e any
trapped air and molsture which has entered it. A vacuum p u m p capable of pulling 29 inches of mercury or
better should be used. .As ue lower the pressure in the air conditioning system. we lower the boiling
temperature of the uater (moisture) that may be present. Then we are able t o pull this water. in the form of
vapor. out of the s!.stem. The following c h a n demonstrates theeffectiveness of moisture removal under a gi\,en
\.acuum
I
C H A R T 2106. SYSTEM V A C U U M C H A R T
CO5IPOLXD G A U G E
R E A D I K G IS l S C H E S
O F 3IERCL'RY V A C U L M
System Vacuum
Temperature " F
27.99
28.89
29.40
29.71
29.82
29.88
100
80
60
40
20
0
For each 1,000feet of elevation aboveseo level, the compoundgauge
reading will be about one inch lower, numerically.
21-56-00
Page 21-23
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
The following steps should be of help when performing this operation.
1. Remove access panel at the rear of the cabin to gain access t o the Schrader service valves.
Ascertain that aU system pressure is released w o r e attempting the
evacuation. (Rejer to Special Sewicing Procedures.)
2. Connect the manifold gauge set to the airplane service valves. (Refer to Service Valves.)
3. The high and low manifold hand valves should be in the closed position. (Refer to Figures 21-5 and
2 1-6.)
4. Connect the center manifold hose to the inlet of the vacuum pump.
Make sure the exhausi port on the vacuum pump is open to avoid
damage to the vacuum pump.
5. S t a n the vacuum pump and open the low side manifold hand valve. Observe the compound. low
pressure gauge needle. it should show a slight vacuum.
6. Continue to operate the vacuum pump until 26 to 28 inches of vacuum is attained on the low pressure
gauge. then extend the operation for another 25 minutes.
7. If the system cannot maintain 26 to 28 inches of vacuum, close both manifold hand valves and 0bsen.e
the compound gauge.
8. Should the compound gauge show a loss of vacuum, there is a leak in the system which must be
repaired before continuing with evacuation.
9 . If no leaks are evident. reopen both manifold hand valvesand continue the evacuation for another 30
minutes.
10. Close manifold hand valves. stop vacuum pump and disconnect center manifold hose from the
vacuum pump.
1 1 . Proceed to charge the system in accordance with Charging the System.
The system should be charged as soon as it has been evacuated.
CHARGIKG T H E SYSTEM.
When the system is completely evacuated in accordance with instructions given in Evacuating the System.
one of the following procedures should be used to charge the system.
Page 21-24
Revised: August 11. 1983
PIPER AIRCRAFT
PA. 32-301/301T
MAINTENANCE MANUAL
I
887
1.
C T L I U O C I C ~ c I I 6Uh U~C C~
L.
).
COUCOUWO GAUGE
V A L V E . LOW C R L I I U R E COUTROL
4.
vALVE.VACUUU COUTIOL
CMAR6lU6 CTLINOLR
9.
1
2
3
6. D n A c u c T
7. I I G M T C L A S S
4
I.
CTLIUOER B A I L VALVE
0.
m.
M10M C R E I I U R E 6 h U O E
V A L V E , MICM C n c a I U n L C O * T @ O L
11.
V A L V E , n t r n 1 6 . COWTROL
5
!I.C M A n C I * L I M E M O I L M O L O E ~
13. m n A c u c T
14.
LOW C
C
IU
IE
I
cMAacI*a
L ~ Y C
15. M I ~ MCICSIURE
CMAROlNG L I M E
W. ) 1 C A T I u G C L L U L U T P L U G
17. V A C U U M C U U C
m.
l9.
20.
O I L * I L L LOCATIOU
UtC.
AISEUILI
RtVR10flAUT D l U U IUCCORT
6
7
I
2 I. R E ~ l I G E l A M TD R U M V A L V E
2 1 VACUUU CUUC VALVE
2). v ~ c u u ur u u r EIMAUST
PORT
24.
13.
26.
21.
28.
29.
30.
31.
TOP CTLIMOEl VALVE
n E r n l a r n A M T OIUU
WCl ITlAm
RErRlGElAWT O l U U O E O U C E ~
CUAIICIUC CTLlMOER M o s t
VACUUU CUUC IUTAKE MOIC
V&CUUU
CUUC I w l T C *
VACUUM CUUC COWER C o n 0
J
Figure 2 1-9. Charging Stand
I
1
I
I
1
I
C H A R G I S G STASD !METHOD.
This i > the preferred method of charging the s!,stem.
- NOTE The jollowing instructions apply to Kent Moore, J23500 charging
stand. (Refer to Figure 21-9.)
I . U'ith the s!stem discharged and evacuated. proceed t o hook-up the charging stand. (Refer t o Figure
21-10.)
2 Fill the charging c!,linder by opening the \.al\.e at t h e base of the chargingc!.linder and filling the sight
glass u i t h two pounds of liquid refrigerant.
3. I f refr~gerant stops filling the sight glass. o p e n the valve at the t o p of the gauge neck assembl!
intermittentl! t o r e l ~ e \ ehead pressure and allow. refrigerant t o continue filling the sight glass t o the required
amount.
4 . \{'hen refr~perantreached the required level in t h e sight glass. close both the val\ae at the base o f the
q l i n d e r and the \ a l \ e at the bottom of refrigerant tank. Be sure the t o p valve is fully closed.
If bubbling occurs in sight glass, reopen the cylinder base vahle
momentarily to equalize drum and cylinder pressure.
21-57-01
Page 21-25
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
5 . Connect the heating element plug t o a 110-volt outlet.
6 . Turn c\ l ~ n d e rsight glass t o match pressure reading o n cylinder pressure gauge. this scale should be
used during ent-ire charging operation.
7. Close loti pressure control v a h e . fully open refrigerant control val\.e and allow all the liquid
refrigerant contained in the charging cylinder t o enter high side of aircraft system.
8. \'hen the full charge o f refrigerant has entered the system. close refrigerant control \,ah e and high
pressure control \ a l \ e .
9 . After completion of charging. close all valves on the charging stand. Disconnect the high and lou
pressure charging lines from the aircraft system. ( A small amount of refrigerant remaining in the lines m i l l
escape.) Replace lines on holder of charging stand t o keep air and d i n out of lines. Open the val\-eat the top of
c!.linder to re1iet.e an!. remaining pressure. then reclose the valve.
10. Reinstall protectke caps o f Schrader valves a n d any access panels previously removed.
1
AIRPLANE COMPRESSOR
METHOD.
This method is the least desirable due t o the requirement of operating the airplane's engine t o run the
compressor.
Ascertain that the area around the airplane is clear and a qualijied
person is at the controls of the airplane.
I . N'ith the system evacuated as outlined in E\.acuating t h e System. connect the refrigerant c h a r g ~ n g
hose t o the manifold (refer to Figure 21-10) and purge the charging hose of air.
2 . Place the refrigerant container on a scale t o observe the amount of refrigerant entering the s!stem.
Open the high pressure \.al\e and add as much refrigerant as possible.
3. Close rhe hiph pressure \ a l \ e . s t a n the engine and operate it at 900 t o I000 R P h l .
4. Operate the air c o n d ~ t ~ o n and
e r set controls t o maximum cooling.
5. Open the ION pressure \ a l \ e and complete charging the s!.stem.
6 Close the lou pressure \she after two pounds of refrigerant has been added t o the s!stem.
7 . U'ith the s!stem still operating. obserke the sight glass in the top of the recei\er-deh!drator tr!
remo\ ing the plastic plug.
8 . The sight glass should be clear of an!. bubbles o r foam. If bubbles or foam are seen passing through
the sight glass. i t is an indication of a low. refrigerant charge in the s!.stem and more refrigerant is r e q u ~ r e dThis
.
check should be made u.ith O A T of 70°F o r higher and with the air conditioner operating.
9. I f more refrigerant must be added t o the system. open the lowmpressure \,al\,e and increase engine
speed to 2000 R P I 1 and obsewe the sight glass. After the sight glass has cleared. close the low pressure \al\ r:
and o b s e n e the pressure gauges. At 1000 R P M the gauge pressure should be 15 t o 20 psi on the loti side a n d
150 t o 100 on the hiph side.
-- NOTE
-
Suspect leaks or an inaccurate scale if two pounds of refrigerant
does not fill the system.
Page 21-26
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
b
axx4Rw
1611
UHE
COlVDENSER
I
RECEIVER
DEHYDRAXR I
SICHT GLASS
SUCTlOlv UNE
--
-
I
-
FITTlNG
EVAPORATOFl
TnlsENOQnOSE
MUST HAVE DEVICE
TO DEPRESS
SCHRPDER VALVE
--
I
'
I
-----
--
1
OPTIONAL METnOO
--
J
WRGING
STAND
PREFERRED METHOD
Figure 2 1 - 10. Charging Hookup
10. Shut off air conditioning system and airplane engine. Then, remove the charging lines from the
Schrader valves with care due to the refrigerant remaining in the hose.
- NOTE A shop cloth should be used to divert escaping refrigerant when
disconnecting the charging hose from the Schrader valve. Recap the
valve.
ADDITlOh' OF PARTIAL CHARGE TO SYSTEM.
I t is possible to top off this system with refrigerant by the following method:
1 . Remo\e the access panel at the rear of the cabin.
2. Connect a charging hose to a refrigerant cylinder and also t o the Schrader valve fitting on the suction
line. (Refer t o F~gure21-10.)
3. Purge the charging hose by allowing a small amount of refrigerant gas to escape at the Schrader \*ahe
fitting.
4. S t a n the engine and operate at 1000 RPM and turn the air conditioner on maximum cool.
5. Remove the plastic plug from the sight glass in the top of the receiver-dehydrator.
6. With a low refrigerant charge in the system, bubbles will be seen passing through the sight glass when
the system is operating.
7. Open the valve on the refrigerant cylinder.
21-27-03
Page 21-27
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
8. .4110\\ refrigerant t o flow into the system until the bubbles disappear from the sight glass.
9. Close the refrigerant \.al\.e and check to see that the sight glass remains clear during s!.stem operation.
10. H'hen the sight glass s1aJ.s clear of bubbles. add a n additional 1 . 4 pound of refrigerant to the s!stem.
(Engine should be operating at 1000 R P M . )
This should be done with OAT at 70°F,or higher, with the air
conditioner operating.
I I . Shut off the air conditioner and engine. Remove the charging hose from the Schrader \ a h e w 11h care
due t o refrigerant remaining in the line.
12. Replace the access panels.
I
C O 3 I P O S E N T SERF'ICE.
COATPRESSOR SERF'ICE.
I t i not a d \ isable to sen.ice the compressor in the field. It should be done by a qualified shop \\ hlch ha?
the special equipment and ~ r a i n e d ~ e r s o n n required
el
t o properly s e n i c e the unit.
Maintenance to t h ~ sunit and its related components is limited t o replacement of u o r n dri\e bell and
magnetic clurch. An! other s e n ice requires remo\,al of the compressor from the s!.stem.
- NOTE A n important factor in air conditioning servicing is cleanliness and
care should be exercised to prevent ditl or foreign material from
entering the S-vstem.All hose and tubing ends should be capped
immediateh-. Any lubrication required in the assemb!v of the
components should be refrigerant oil of the type used in the
compressor.
The r e m o ~ a lof the compressor requires a complete system discharge. (Refer to Discharging.)
I . Be certain the circuit protector is off for the air conditioning system.
2. R e m o \ e the engine cobling and right front baffles.
3. Disconnect thc electrical leads to the magnetic clutch on the compressor.
3. Depre5suri7e the air conditioning system.
Page 21-18
Revised: August 11. 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
5.
R e m o \ e the suction and discharge lines from the s e n i c e valves on the compressor.
-NOTE
-
A I1 open lines should be capped immediate& t o prevent dirt and
moisture from entering the system.
6 . Loosen the bolt securing the compressor idler pulley t o release the belt tension and remo\.e belt from
compressor pulle!.. ( D o not force belt o\,er the pulleys.)
7. Support the compressor and remove the 6 bolts securing the compressor to the engine mounting
brackets.
COSIPRESSOR INSTALLATIOS.
1 . Place the compressor to the mounting brackets. Install the six bolts and progressively torque to 14- 17
foot-pounds. (Safety all bolts a,ith .032 safety wire.)
2 . Check the oil le\.el in the compressor in accordance with instructions given in Checking Compressor
011
3. Place d r i ~ belt
e o \ er clutch pulle!. and adjust the alignment of the pulleys and belt in accordance u ith
instructions gl\en in Replacement of Compressor and or Alternator Drive Belts.
Do not force the beh into thepulley sheave. If necessary,remove the
idler assemb!,,.
Connect the discharge and suction lines to their respective service valve fittings.
5 . E\acuate and charge the s!.stem per E\.acuating the System and Charging the S!,stem.
4.
If the air conditioner is to be operated on the ground for servicing.
the test area should be clean and free of any loose objects lying on the
ramp. Only the service vahtes located on the evaporator assemb!v
should be used for testing.
21-58-03
Page 21-29
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHECKISG CO31PRESSOR OIL.
T h e oil lei el 3hnuld be checked an!. time the system is discharged. The following steps should be follo\r sd
to perform this check:
1 . I t uill he necessar! to discharge the system. (Refer t o Discharging.)
2. Fabricate an oil dipstick. (Refer t o Figure 21-1 1.)
3. R e m o \ e the oil plug. ( A .375 inch plug in the top side of the compressor crankcase.)
4 . Before inserting the dipstick. the crankshaft Woodruff key should be located in the up position. (The
front face of the compressor clutch is marked with a stamped "K" indicating the key position.) The oil lelel
should be measured from the low.est point in the crankcase. Use the long end of the dipstick. (See Figure 2 I I I.)
5 . N'ith the compressor in the installed position use Chart 2107 t o determine the amount of oil in the
crankcase.
h than 6ounces of oil. %'hen oil is added the Is\ el
6 . The compresror should ne\.er be operated ~ , i t less
should not go a b o \ e 10 ounces. P ~ p e rrefrigerant oil PMS-L2000 or equi\,alent 500 \iscosit!. refrigerant o ~ l
mu51 be used.
7 . Elacuate and charge s y t e m . ( P e r E\.acuating the S!.stem and Charging the S!stem.)
The 10 ounce oil level is required in compressors installed on nen*
systems. Some oil is distributed in the system during operation.
Replacement compressors should be charged with 10 ounces o j oil.
The oil plug should not be removed with pressure in the system.
1
C H A R T $107. C O M P R E S S O R O I L C H A R G E
011Charge Ounces
Dipstick R e a d ~ n gInches
6
8
10
1.7 16"
1 .00"
1-3 16"
16
1-15 16"
Page 2 1-30
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAIKTENANCE MANUAL
4078
-
c
4.68
w
- . 1 .so
THIS END FOR
HORIZONTAL
MOUNT
NOTE. 12 NOTCHES 1 /8 INCH APART
STARTING AT EACH END.
T H I S END FOR
VERTICAL
MOUNT
O I L CHECK PLUG
( T Y P I C A L TWO SIDES)
I
I
I
Figure 2 I - I I . Compressor and Fabricated Oil Dipstick
REPL.ACE31EST OF C O M P R E S S O R D R I V E BELT. (Refer t o Figure 21-12.)
I . R e m m e the old belt b! remo\ ing the spinner. propeller. nose cow I. engine baffles as required. starter
ring gear arsembl! and d r i \ e belt.
2 Place the ne\i belt in 11s appropriate positions on the starter ring gear shea\es.
3 Re~nctallthe ctarter ring gear assembl!. propeller and spinner.
4 . Route the belt t o the proper p u l l e s h e a i e a s shown in Figure 21-12,
D o not force the beh into the pulley sheave. Remove the idler
assemblies, if necessary, and the alternator lower mounting bolts in
order to install the belt.
21-58-05
Paee 21-31
Revised: .August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
1
FIE
1
*(YINAL D I Y f = l O Y
fOR
COYCRESSOR ~ E L ALIGNMENT
T
)
I
i
S T R b I G U T EDGE
VIEW A
YlSALlWYfNl
-
1
'STRAIGHT E W E
3 A T W LINE
1
I
I
IFORWARDSURFACE O f n I N G G E A R )
I
6
S49
VIEW A
*a*
BRACKET ASSY P , N 79584 2
ADO OR REMOVE SHIMS P ' U 6 2 8 3 3 83
AS REQUIRED T O A L I G N IDLER Is
#EL1 C U N E
i
;
,
I
I
i
I
I
i
I
A D D OR R E W O V E 5-,us IP h
62833 8 3
AS R E O u l R E C F O G
P P C D E P COVPRESSOP 8 E . l
ALIGLIVE~~
1 RlNG GEAR
2 COMPRESSOR IDLER PULLEY
3 COMPRESSOR
4 COMPRESSOR
5 ALTERNATOR
6 RlNG GEAR
7 COMPRESSOR BELT
8 COMPRESSOR IDLER SHEAVE
9 COMPRESSOR SHEAVE
10 RlNG GEAR SHEAVE
1 1 ALTERNATOR BELT
1 2 ALTERNATOR SHEAVE
13 ALTERNATOR IDLER SHEAVE
F ~ g u r e2 1 - 12. C o m p r e s s o r a n d Alternator Belt Installation
21-58-05
Page 21-32
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
5 . Check the belt a n d pulle!. alignment of the compressor a n d o r alternator b! the f o l l o ~ i i n gmethod.
A . .4 d;itum line must be established f o r checking belt and pulley alignment. A nominal d i m e n , ~ o n
must be established hctween the forward edge of the compressor belt a n d the forward machined 3urface ot'thr.
ring gear. This dimenlion should be taken at the ring gear assembly where the belt is in its shea\e. T h e a m o u n t
of misalignment can then be determined at the other pulley sheaves by using a stiff straightedge of suf'f~cient
length t o extend from the front of t h e ring gear t o the component shea\.es.
a
Insure adequate ring gear surface contact to provide a solid basefor
the straightedge.
I
B. Obtain a basic measurement f r o m the t o p of the ring gear by measuring the w.idth of the starter
ring gear plus the dimension from t h e forw,ard machined surface of the ring gear to the forward edge of the
compressor dri\ e belt. (Refer to Figure 2 1-1 2.)
C. T h e check a n d a d ~ u s t m e n t sof the compressor a n d o r alternator d r k e belts require different
procedure.. Refer to following appropriate instructions.
6 Compressor Belt Alignment: ( R e f e r t o Figure 21-12.)
4
Place the straightedge against the right forward side of the ring gear a n d measure belt alignment
at c o m p r e s ~ o rshea\e t Point-B).
B. \leasure belt alignment at the compressor idler pulley (Point-A). T h e belt misal~gnmcn:21
Point-A should be half the misalignment of Point-B and the dimension at the t o p of the ring gear and In rhs
same direction fore and aft.
C If at Point-A nominal misalignment is not within + - .030o f a n inch. a s obtained from Step R .
add o r r e m o \ e shimc as required. Belt alignment should be made a s close t o nominal a s shimc \4 i l l ~lllo\\
4lternator Belt .4lignment. (Refer to Figure 2 1 - 1 2 . )
.4 \ \ ' ~ t hthe alternator belt installed. align the idler pulle!, in t h e belt plane b! adding or rsmo\ Ing
shimc. P K 628.7.7-82 as required.
ADJI'ST\IENT OF DRI\'E BELT TENSIOS.
T h e ad!ustment of the compressor and or alternator d r i t e belts is \.cry important to obtain long belt ! ~ i c
and proper component operation
I . Adlust new compressor belt t o 120 pounds span tension and new alternator belt t o 90- 100 pound.
span tenslon. \+'hen using the p l a s r ~ ct18pealternator belt adjust the tension at 65-70 Ibs. for neu belt. 1 .c. 2
calibrated belt tension gauge.
- NOTE The higher tension specified jor a new belt is to compensatejor the
initial stretch that takes place as soon as it is operated These higher
tension values should not be applied to belts which previously have
been used. See tensions noted below for used behs.
2
Install engine baffles if remo\,ed and install engine cowling.
21-58-06
Paee 2 1-33
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
3. R u n the engine for a 15 minute period at 1200 RPM.
-
-- HTAR,r\'l.rVG
If the air conditioner is to be operated on the ground for servicing.
the test area should be clean andfree of any loose objects lying on the
ramp. Only the service valves located on the evcrporator assembly
should be used for testing.
4. Shut d0u.n engine and recheck both belt tensions. I f compressor belt tension falls as low as 60 pounds.
retension t o 80 pounds. If alternator belt tension falls below 50 pounds. retension t o 70 pounds. The plastic
t!,pe alternator belt should be between 35-40 Ibs.
5. This tension check should be made at e\.ery 100 hours or annual inspection. whiche\er occur< first.
6. Check all idler and bracket bolts for safet!, and replace engine cowling.
31AGNETIC C L U T C H R E M O j ' A L . (Refer to Figure 21-1 3.)
I
Remo\ e the self-lock~ngcapscreu and washer from the compressor shaft.
Insen a 5 8- 1 1 L\C-ZB bolt In the threaded portion of the h u b and tighten. The pressureexerted tr!
the bolt on the end of the compressor crankshaft will force off t h e rotor pulley assembly u ithout damage to the
clutch or compressor
2
Do not use a n.heelpuller on the outer flange of the pulley. This can
damage the pulley grooves or clutch bearings.
-7. R r m o \ e the four bolts securing the field assembly against the compressor bosses and remoie rhe
bolts. washers. and field assernbl!
41 3
1 CAPSCREm
2 ROTOR PULLEY ASS Y
3 CAPSCREWS A N D LOCK WASHERS
4
FIELD ASS Y
5 COMPRESSOR
1
1
F ~ g u r e2 1 - 13. Magnetic Clutch
21-58-08
Page 21-24
Revised: August 1 I . 1983
•
PIPER AIRCRAFT
PA-32-301 /301'.'
MAINTENANCE MANUAL
MAGNETIC CLI'TCH INSTALLATION. (Refer t o Figure 21-13.]
I . P o s ~ t i o nthe field assernbl!. against thecompressor bosses. with the electrical leads t o the c!.linder side
of the compressor.
2 . Secure the field assembl! with four capscrews and lock washers. d o not torque at this time.
3. Connect the electrical lead from the field assembly.
I
I
- NOTE -
I
The compressor shaft must be clean and free from burrs.
4. Slide the pulle! assembly over the field assembly and onto the crankshaft. n o n torque the field
assembl! 85 t o 120 inch-pounds. T h e n secure pulley assembly with washer and new. self-locking capscreis.
Torque the capscreu to 180 to 240 inch-pounds.
- NOTE -
1
If the clutch is not engaged while tightening the capscrew, insert a
spanner into the holes provided in the armature face.
5 . Spin the pulle! by hand to check for any interference between the field and rotor pulle! assembl~es..A
rubbing nolse can he heard as the pulley rotates if there is interference. T h e rotor pulle! assembl! mu,\ he
remoied and the m o u n t l n of the field assembly adjusted until the interference is eliminated.
~
REFRIGERANT LINES A N D ROI'TISG.
a
The refrigerant lines in this aircraft are flexible high pressure hoses and should be handled accord~ngl!
The hoses in the pouer plant area are routed so as to pro\ ide maximum protection from the heat and a h r a > ~ o n .
The! couple at the f ~ r eu a l l to hoses routed through the two inboard. external hat section on the borrom o t r h t
fuselage. up through the floor to the condenser a n d e\.aporator in the tail cone. T h e discharge is in the r i g h ~
hand secr~onand the suction In the left.
- NOTE Before any of the hose couplings are uncoupled, the system must be
complereh, discharged. (See Discharging.)
21-58-10
Page 21-35
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
REMOVAL O F RECEIVER-DEHYDRATOR.
This unit is mounted on the inboard side of the evaporator assembly housing.
1 . Discharge the s!.stem of all refrigerant. (See Discharging.)
9. L!ncouple the refrigerant lines at the receiverdehydrator. (See Special Senicing Procedures.)
3 . R e m o i e the clamp attaching the unit t o the evaporator housing.
This part is not serviceable, it must be replaced. The
receiverdehydrator should be replaced when the system has been
operated wirhour a charge or is lejr open.
I S S T A L L A T I O S O F RECEIVER-DEHYDRATOR.
I . Slip the mounting bracket around the receiver and put i t in place on the evaporator housing u i r h the
tube fitr~ngon top. .Align the fittings to the proper line before securing the mounting bracket.
Torque the fittings. (See Chart 2104.)
•
2 E \ a c u a t e and recharge the s!stem in accordance with Evacuating the S!.stem and Charglng t h ~
S! stem.
COSDESSER.
RE51Ol'AL O F C O S D E S S E R .
The condenser is mounted in a frame assembly located in the bottom of the fuselage between %ration>
156.00 and 19 1.00.
I . D ~ s c h a r g ethe s!,stem. (See Special Servicing Procedures and Discharging.)
2 . R e m o i e access panel from the aft bulkhead of cabin.
3. R e m o l e the i o r u a r d cover panel.
4 . Uncouple the suction and discharge hoses at the condenser fitting. (See S p e c ~ a l S e r \ i c ~ n g
Procedures.) Remo\e the hose clamps holding the hoses t o the condenser frame.
5 . R e m o \ e the A \ - 3 bolts from the upper ends of the side hinges and rod ends.
6 . Support the condenser assembl! and remove the bolt attaching the actuating rod t o the condenser
assembl! .
7. L o n e r the aft end of the assembl! on the piano hinge at the forward end of assembl!.
8. R e m o \ e the eight s c r e w attaching the piano hinge t o the condenser frame assembly and remo\ e from
aircraft.
9. T o remo\e condenser core from assembl!.. remove the screws in the side mounting frame.
Page 21-36
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I S S T A L L A T I O \ OF C O S D E K S E R .
In3trlll thc condenser core t o the frame assembly with the hose fittings forward and up.
I
2 Place the condenser and frame assembl!. t o the fuselage frame mounting bracket a n d insert the ( P I
screws into the piano hinge.
1 Attach the side hinges a n d actuating rod a n d rig per Condenser Assembl!. R i g i n g Instructionl;
4
Seal and couple the hose fittings (seal with Loctite refrigerant sealant applied t o flanges onl! ).
5 . .Adlust the condenser in accordance with Condenser Assembly Rigging Instructions.
6 , Seal all around f o r u a r d cot8erpanel ( a n d aft cover panel if remo\,ed) with Permagum Bead K o . 576
purchased f r o m Prestolite Engineering Cornpan!,. (See Figure 21-14.)
-- NOTE
-
U'henever it is necessary to remove and replace the cabin rear panel,
it should be replaced and sealed in the original manner. I j i t is not.
because o fthe low pressure area in the cabin, exhaust gases may seep
into the cabin.
,Ifake a carbon monoxide test on ground and in flight with and
w'ithout the air conditioner operating. Presence of C 0 2 shall not
exceed I part in 20,000.
C O U D E S S E R DOOR ACTUATOR.
a
T h e actuator I G on a brachet mounted hetween two bulkheads in the tail cone i t is coupled t o the
condenker aksembl! t h r o u ~ ha bellcranh mounted t o a brachet on the bulkhead aft of the condenser T h e
actuator tra\ el 15 controlled b! r u o 11m1ts u ~ t c h e sBoth
.
the up a n d d o w n sw Itches are located on the acluator
Refer to F ~ g u r e21-1-l for the s u ~ t c hlocatlon5
C O V D E V S E R ASSE31BL1' RIGGING INSTRUCTIONS. (Refer t o Figure 2 1-13.)
I
T h e condenser as\emb\! is actuated b! a n electric motor through bellcranks. push rods and limit s u itches.
I t 1 5 nrcessar! for the condenser d o o r t o fit flush with the fuselageskin. and w.ith increased force along the
foru ard edg: The follou ing steps ill help accomplish this requirement:
I . A d ~ u c topen l ~ m i tsuitch t o open the condenser d o o r 5.00 + - .50 inches when measured from the
leading edge ~i the door t o the fuselage skin.
2 . .Ad~u.;tside push rods s o that a vertically measured gap of . I 6 of a n inch exists along the trailing edge
of the door a t the instant the forward edge of the d o o r becomes flush with the fuselage skin.
1. \i~ t hthe door full! closed adjust the "CLOSED" limit switch s o that the actuator tra\els a n
additional . I 2 o f an inch after the d o o r is full!. closed. this is necessan t o preload the mechanism. (Refer t o
F ~ g u r e21-11. \'ien .4-.4.)
4 . C!cle the assembl! se\i*ral times t o be certain it operates properiy without binding
21-58-18
Page 21 -37
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
1788
SEAL ALL AROUND FORWARD AND AFT COVERS WITH PERMAGUM BEAD NO 576
PURCHASED FROM PRESTOLITE ENGINEERING COMPANY
1 ACTUATING TRANSMISSION ASSY
2 BELLCRANK ASSY (CONDENSER)
3 PUSH ROD ASSY
4 BELLCRANK-ASSY (MECHANISMI
5
6
7
8
9
10
OPEN LIMIT SWITCH
CLOSED LIMIT SWITCH
CONDENSER
CONDENSER DOOR
PUSHROD
TRANSMISSION MOTOR ASSY
22 NOM CLEARANCE
PRIOR TO PRELOAD
VIEW A-A
10
w
01
D
?
Figure 21- 14. C o n d e n s e r Air Scoop Installation
2 1-58- 18
Page 11-38
Revised: Februar! 19. 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAIIVTENANCE MANUAL
C368
TO EVAPORATOR
V A L V E ASS'Y
CAPILLARY C O I L
!
F R O M RECE l VER
DEHYDRATOR
F ~ g u r e2 1 - 1 5. Expansion \'al\e
I
RE\1OLV.AL O F EXPASSIOS I'ALVE. (Refer t o Figure 21-15.)
The expansion \ a l \ e is located in the evaporator assembl!. between the recei\.er drier and the e\-apnrator
inlet. The capillar! coil is attached to the e\,aporator outlet line.
I . R e m o t e the necessar! access panels and discharge sJ8stem.
2 . R e m o i e the capillar!. coil from the outlet line. ( D o not kink the capillar! tube.)
3. L'ncouple all related tube fittings. (See Special S e n i c i n g Procedures.)
If
this part is not serviceable, ir musr be replaced with a new part.
1 . Install the expansion \ a l \ e in the inlet line of the e\.aporator core by coupling the related fitt~ngs.
(Seal all couplings u i t h sealant applied to tube flanges onl!..) Torque fittings per Chart 2105.
2 . Secure the capillar!. coil to the e\.aporator outlet line.
3 E ~ a c u a t eand charge the s!.stem. (See Evacuating the System and Charging the S!stem.) Chech for
leahs (See Checking the S!.stem for Leaks.)
4 . Replace access panels.
21-58-21
Page 21-39
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
EVAPORATOR.
I
R E M O j ' A L O F EF'APORATOR.
T h e e t a p o r a t o r assembl!. consists of the evaporator core. receiver-deh!drator. espansion \ a I \ e .
circulating fan a n d pressure switch together with necessar! housing and plumbing. T h e housing 1s fabr1catt.d
of thermoplastic material. The condensed moisture is dumped o\.erboard through a hose clamped to a f~ttlng
on t h e bottom o f the e\aporator housing.
T h e e\,aporator assembl!. is located behind the cabin rear panel. attached to the mounting panel \\ ith I _ '
screws and washers and a bracket securing the back t o the mounting panel.
I. R e m o i e air conditioning filter cover. filter and rear access panels.
- NOTE Discharge the system before disassembling any components for
service.
2 l'ncouple the liquid l ~ n efrom the inlet side of the receiver-dehydrator and the suction line from the
e i a p o r a t n r core outlet. (See Special S e n i c i n g Procedures.)
3 . Disconnect the related electrical wires.
4 . Rernme flexible air duct from housing outlet. Remo\*e drain hose from housing
5 R e m o i e temperature probe from e\aporator housing.
6 . R e m o i e the screus attaching the support bracket and evaporator housing to the mounting panel
R e m n i e the assemhl! through the access hole in the bulkhead.
(
INSTALLATIOS OF EF'APORATOR.
I . Cement gabket in place on the flanges of the e\.aporator housing and attach the largc end of the
mounting gasket t o the back of the housing.
2 Install the housing through the access hole with the air duct outlet on top. hlate the m o u n t ~ n gtlangc..
t o the matlng surface of the mounting panel and insert the screws. ( D o not tighten at this time.)
3. Line up mounting bracket w.ith mating holes in mounting panel. insert screws and tighten. T ~ g h t c n
screws in the flange at t h ~ stime. Be certain a s k e t is in place. T h e flange must h a l e an air tight seal
3. Couple the suction and discharge lines t o their respective fittings (apply Loctite refrigerant sealdnt to
rube flange!. on]) ) .
5 . Eiacuate and charge s!'stem. (See E\.acuating the S!.stem and Charging the S!stem.\
6. Check ior leaks (see Checking the S1,ster-n for Leaks) if n o leaks are detected. Seal and ~ n ~ t aaccc\*
ll
panel on e\aporator housing.
7. Couple flexible air duct and drain tube.
Page 21-40
Revised: August 1 1 . 1983
PIPER AIRCRAFT
PA-32-3C.1/301T
MAINTENANCE MANUAL
8. Make and check electrical connections. (Refer t o Figure 21-17.)
9. Check operation of blower and refrigerant systems.
0 . install rear bulkhead panels. Be certain to real. (See W A R S I I C . )
- WARNING H'henever it is necessaol to remove and replace the rear cabin panel,
it should be replaced and sealed in the original manner to prevent
exhaust from entering the cabin. Ajter removing and replacing the
rear panel, conduct a carbon monoxide test on the ground and in
flight with and without the air conditioner operating. Presence of
C 0 2 shall nor exceed one part in 20,000.
1T I 4
-
- ---
'
1
__33
-
+
@la
4
I
I
<
---A1
b - d
3
I
b
-.
1
-
-
F
r-
WRAP TAPE AROUNDTHERMO.
STAT CAPILLARY LEAVING SERVICE PORT ACCESSIBLE
-
1 SIGHT GLASS
1
\
-- -t
A
'
l
-
2 SERVICE VALVE (SCHRADER, (HI)
3 CAPILLARY COIL
1 HIKISING ASSY
5 SERVICE VALVE (SCHRADER) (LOW)
6 RECEIVER DEHYDRATOR CLAMP
7 RECEIVER DEHYDRATOR
8 PRESSURE RELIEF SWITCH IRANCO)
9 EXPANSION VALVE
10 OUTLET HOSE
Figure 2 1 - 16. Components Installation
21-58-24
Page 21-41
Revised: August 11. 1983
1G3
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
*
1626
DOOR OPEN LIGHT
BWWER
THERMOSTAT
1
SHOWN WITH AIR CONDITIONING FAN SWITCH IN OFF
POSITION MANIFOLD PRESSURE NOT ABOVE 34 INCHES
of MERCURY AIR CONDITIONING SWITCH IN ON POSI.
TlON FREON PRESSURE BELOW LIMIT THERMOSTAT
CALLING FOR COOLING AND CONDENSER DOOR
CLOSED
Figure 2 1 - 17. Air Conditioning \'iring Schematic (Earlier Models)
Page 21-42
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-6.-
BLOWER
YOTOR
*M
1
TMERYOSTAT
OPE'.
--
I
'
!
SHOWN WlTH AIR CONDITIONING FAN SWITCH IN OFF
POSITION. MANIFOLD PRESSURE NOT ABOVE 34 INCHES
OF MERCURY. (PA-32-301T ) THROlTLE NOT WIDE OPEN
lPA.32-301) AIR CONDITIONING SWITCH IN ON POSI.
TION. FREON PRESSURE BELOW LIMIT. THERMOSTAT
CALLING FOR COOLING. AND CONDENSER DOOR
CLOSED
F ~ g u r e2
1 - 16. Air C o n d ~ t i o n i n gWiring Schematic (Later h1odell.i
21-28-24
Page 21-43
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
PRESSI'RE RELIEF SWITCH (RANCO).
T h e pre<\urr relief sw ~ t c hautomatically preients the system from o \ e r pressurlzatlon b! breah~ngthe
electrlca! clrcult t o the magnetic clutch. stopplng the compressor until pressure 1s reduced The 5u11ch I,
located in the l ~ n ebetween the recener and expansion \ a l \ e .
- NOTE Before the reliejswitch is removed, the air conditioning system must
be discharged. (See Discharging.)
ELECTRICAL ISSTALLATIOS.
T h e electrical s!.stem w iring and components are installed and routed in the con\entional aircraft manner
The uiring harness is connected to switches in the climate control center o n the right side of the instrument
panel. The harnesses cross the instrument panel t o the left side w,here two (21 wires are taken off for the
compressor clutch. The harness then passes aft along t he left side of the fuselage w here it connects to the hlou er
motor.'pressure relief suitch and the condenser actuating motor.
A D J t ' S T M E S T O F THROTTLE SM'ITCH.
T h e throttle sit itch is mounted forward a n d belou, the throttle a r m . T h e sw itch must be ad!usted so it \I 1 1 1
actuate at the last Quarter inch of full ooen throttle tra\el.
The switch shduld he positioned so'the throttle a r m contacts the center of the suitch actuator b u ~ ~ o n
There are three fuses located behind the air conditioning s\-stem control panel. X 20 a m p c1rcu:t breaArr
mounted in the clrcult breaker panel protects the complete air conditioning electrical s!stem
Page 21-41
Revised: August 11. 1983
a
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MAKL'AL
THIS PAGE ISTEUTIOSALLI' LEFT B L A 3 K
CHAPTER
AUTO FLIGHT
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 22 ALTOFLIGHT
TABLE OF CONTEh'TS/EFFECTIVITY
CH.4PTER
SECTIO\
SUBJECT
22-00-00
22-0 1-00
22-02-00
SUBJECT
AC TOFLIGHT
\on-P~perAutomated Flight Control System
Equ~pmentContacts
P~perAutomated Flight Control System
Equipmen1
GRID
NO.
EFFECTII'ITI'
lGlO
A 8-83
lGlO
A 8-83
lGl I
A 8-83
22
- Cont./Effec.
Page - 1
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANVAL
D u e t o the u idc \arit! of A.F.C.S. (Automated Flight Control S!stem)options. it is mandator! to (olio\\
the s e n k e literature published by the indi\,idual manufacturer o f the A.F.C.S. equipment installed in an\
particular airplane. This include3 mechanical s e n i c e such as: adjusting bridle cable tension. ser\ o remo\ a1 and
installation. s e n o clutch adjustments. etc.
S O N - P I P E R A.F.C.S. EQL'IPMEIVT CONTACTS.
Refer t o the following list of Autopilot Flight Director manufacturers t o obtain ser\ ice direction. par15
support. and sen.ice literature.
Bendis A\ ionics Di\ ision
2 I00 \.M'. 62nd Street
Fort Lauderdale. Fla. 333 I0
(305) 776-4 100 TM'X 5 109559884
Collins General A\ latlon Dl\ ~ s l o n
Rochuell lnternatlonal
Cedar R a p ~ d k .l o u a . 52406
( 319) 395-3625 T e l e x 464-41 1
E d o Corporation - A\ ionics Di\ ision
Bos 610
Municipal .Airporr
hl ineral Wells. Texas. 7606'
t 8 17) 3 3 - 2 5 17 Telex: 76067
K ~ n gRadio Corporation
400 \orth Rodgers Road
Olathe. Kansas. 66061
( 9 1.:) 781-0400 Teies: 4-2299-Kingrad
Sperr!. ~ l i ~ S!s~erns
h!
A\ ionics Di\
8500 Balboa Bllrd.
P . O . Box 9028
\'anSu!,s. C.4. 91409
( 2 13) 8 9 4 4 l l I Telex: 65- 1367
Global l a \ . ~ g a t ~ o n
2 143 M ichelson Drl\ e
(714) 851-01 19
Page 22-01
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
PIPER A.F.C.S. EQI'IP\IEST.
In thc ca4e olearl! models. Piper PIutoPilot equipment bears the Piper name. and the appropriate P ~ p e r
Autopilot F l ~ g h tD~rectorS e n i c e Manual shall be used.
- NOTE If a Roll A xis-onlv A utopilot is installed, or if no A utopilot is
installed, consult the Piper Pitch Trim Service Manual 753 771jor
manual electric pitch trim service information.
The f o l l n ~ i n pis a complete listinp of Piper A.F.C.S. equipment service literature. I t is imperati\e t o
correcrl! identif! the AutoPilot s!,stem b! "faceplate" model name. in order to consult the appropriate zer\ ice
manual. Each manual identifies the re\.ision le\el a n d re\.ision status a s called out on the Master Part6 Pricc.
List - Aerofiche publirhed monthl) b! Piper. Consult the aircrafts parts catalog for replacement parts.
'iAX1E
PIPER PART F O .
AutoControl 1 1 1 8: .4ltimatic I I 1
4uroControl I l l and A l t ~ m a t i cIll a n d lllB
4uroControl l l l B a n d AltiMatic 1119-I
.4ltiMatic IIIC
4 l t 1 l l a t 1 c\ ' and \ ' - I
. A l t ~ f l a t ~\ 'c F D and \ ' F D - l
.Alriflat~c\ F . D A . P . & :S A . P .
AutoFl~te
. A u ~ o F l ~It1e
P ~ p c rPitch T r ~ m~Ylanual-Electric)
22-02-00
Page 22-02
Revised: August 11. 1983
'
a
CHAPTER
COMMUNICATIONS
PIPER AIRCRAFT
PA-32-301 / 301 T
MAINTENANCE MANUAL
-
CHAPTER 23 COMMUNICATIONS
TABLE O F CONTENTS/EFFECTIVITk'
SUBJECT
23-20-00
23-2 1-00
27-21-01
3 2-2 1-02
-.
?2-2
- - 1-0.;
D4TA TRASSMISSION AND AUTOMATIC
C4LLIYG
Ernergenc! Locator Transmitter - Narco
Batter! Remo\ al and lnstallat~on
Test~ngEmergent! Locator Transmitter
Detcr~pt~on.
Operat~onand Test~ngof
P~lot'sRemote S u ~ t c h
GRID
TV 0.
1G14
IG14
lGl4
IG17
EFFECTI\'ITJ'
A 8-82
5-80
lGlP
23 - Cont./Effec.
Page - 1
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
T h i i chapter contain< information necessar!. t o perform operational checks of the Emergent! Localor
Transmitter (.ELTI. n i t h and nithout a pilot's remote switch. Included are the appropriate remo\al and
installation instructions t o facilitate batter! replacement.
I
D A T A TRANSMISSION A N D AL'TOMATIC CALLIKC.
EMERGENCl' LOCATOR TRASSMITTER (KARCO).
T h e electrical p o u e r for the ELT is totall!supplied by its own self-contained alkaline batter!. The batter!
must be replaced on or before the replacement date marked on battery pack label. I f the transmltter ha< becn
used in an emergent!. situation or it has more than one hour of accumulated test time. the batter! mu+t be
replaced.
BATTER)' REMOVAL A N D ISSTALLATION.
T h e ELT is located on the right side o f the fuselage aft of sta. 259.30. (Refer t o Flgurci 2 7 - 2 and '3-3 )
I . R e m o i e the access panel on right side of the fuselage.
2 . Set the 0\ O F F A R M suitch on the transmitter t o OFF.
3. Disconnect antenna coasial cable and the remote switch wires from E L T .
1. R e m o \ e ELT from its mountins bracket b!.releasingthe latch on the strap and s l i d ~ n g t h cELT otirhe
bracket
5 . Extend the portable antenna. (Refer to Figure 23-2.)
6 l ' n < c r e u the four screus that hold the control head t o the batter! casing and slide apart.
I . Disconnect the batter!
terminals from the bottom of the circuit board.
8 . D~hcardold batter! pach. ( D O S O T EXPOSE T O F L A M E . )
The battery pack is shipped with a sealant on the inside lip so that o
water tight seal will be retained. DO NOT REMOI'E THIS
SEA LA.1'7.
9. Connect neu batter! pach terminals t o the bottom of the circuit board.
10.
replace
I I.
I .
Reinsert the control head section into the b a t t e r pack being careful not to pinch an! u.ire5. and
the four screns. I f the four holes d o not line up. rotate the batter! pack 180: and relnsert
S l ~ d sthc' portable antenna back into the stotved position.
Place transmitter into ~ t mounting
s
bracket and fasten the strap latch.
Page 23-01
Revised: August 11. 1982
a
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
CONN
R 499
0
-
i
Figure 23- 1 . Emergency Locator Transmitter Schematic ( h a r c o )
I
1 . Connect the antenna coaxial.cable to the E L T and ensure that the contact separator is inserted
between the antenna contact finger and the portable antenna. (Refer t o Figure 23-3.)
14. Connect the remote su.itch u-ires.
15. Press RESET b u t ~ o nand set 0 5 OFF A R M switch I O A R M .
16. Slake a n entr) in the aircraft logbook. including the neN8 battery expiration date.
I i. .A unit operat~onalcheck ma!. nou. be performed on the ELT. (Refer to Testing Emergent!. Locator
Transmitter.)
-- NOTE
-
Inspect the external whip antenna for any damage. A void bending
the whip. Any sharply bent or kinked whip should be replaced.
Antenna damage may cause structural failure of whip in flight.
23-21-01
Page 23-02
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ON-OFF-ARM
ANTENNA
0 FULL LENGTH
Figure 23-2. E L 1 Portable Folding Antenna (h'arco)
1966
CONTACT
SEPARATOR
PORTABLE ANTENNA BLADE
FIXED ANTENNA'S
CABLE CONNECTOR AND
TO REMOTE SWITCH
A
Figure 23-3. E L 1 Using Fixed Aircraft Antenna (h'arco)
Page 23-03
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301
/301T
MAINTENANCE M A N U A L
TESTING EMERGENCY LOCATOR TRANSMITTER.
The transmitter operates on the emergency frequencies of 121.1 and 241 MHz: both of these frequencies
are monitored by the various FAA installations. Before performing any operational test of the ELT. the
following precautions should be observed:
Testing oj an EL T should be conducted in a screen'room or metal
enclosure to ensure that electromagnetic energy is not radiated
during testing. I j a shielded enclosure is not available, testing may be
perjormed in accordance with the following procedures:
I . Test should be no longer than three audio sweeps.
2. If the antenna is removed, a dummy load should be substituted
during the test.
3. Tesi should be conducted only within the time period made up
of the first jive minutes ajter any hour.
4. If the operational tests must be made at a time not included
within the jirst jive minutes aftor the hour, the test should be
conducted with the closest FAA Tower or Flight Service
Station.
Consult FA A Advisory Circular A C 20-81for detailed information
concerning the above caution.
I
1
I
' '
I . Remo\e the access panel o r cover t o gain access to the transmitter.
2 . Turn the aircraft master switch 0 3 .
3. Tune the aircraft communications receiver volume u p until a slight background noise is heard
-NOTE
-
Ij the aircrajt is not fitted with a communications receiver, request
that the rower listen for your test.
4. On the transmitter. set the OK,A R M . , O F F switch t o the ON position. Keep the switch in this
position for onl! a few seconds: then set to the O F F position or A R M if there is no OFF. Return to the .4R31
position.
I
- NOTE The test transmission should hove been picked up by the aircrajt
communications receiver and/or control tower. During cold
weather, there may be a slight delay before transmission occurs.
5 . A transmitter w.hich is functioning properly should emit a characteristic downward swept tone.
6. M'hen the test is completed.ascertain the transmitter Oh';ARMiOFFswitch is in the ARM position.
23-21-01
Page 23-04
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
1
8206
C:
i
c
E
L
AVIONICS M A S T E R R E L A Y
1983 M O D E L S
w
v.
I,'
Figure 23-4. A ~ i o n i c sMaster and Emergency Switch Circuit
7 . Place the access panel on the right side of the fuselage aft of sta. 259.30 and secure with the
appropriate s c r e w .
- WARNING H'henever the unit is checked by moving the transmitter
O.V/ARM/OFF switch from the A R M t o the ON position, it must
then be moved to the OFF position, ijthere is one, before reverting
to the A R M position again.
-- C A UTION
-
C'nder normal conditions, the transmitter switch must be set to
A RAM.
Inspect the external whip antenna for m y damage. A void bending
the whip. Any sharply bent or kinked whip should be replaced.
Antenna damage may cause structural failure of whip in flight.
DESCRIPTIOS. OPERATION A N D TESTING O F PILOT'S REMOTE SWITCH. (Refer t o Pilot's
Operating Handbook.)
Page 23-05
Revised: August 1 1. 1983
a
'
CHAPTER
ELECTRICAL POWER
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MAN-UAL
-
CHAPTER 24 ELECTRICAL POWER
TABLE O F CONTENTS/EFFECTlVlTY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
GRID
KO.
EFFECTIVITY
GESERAL
Description and Operation
Troubleshooting
D.C. GENERATION
Alternator System - Prestolite
Description of Alternator
Checking Alternator System
Service Procedures
Overhaul of Alternator
Disassembly of Alternator
Inspection and Testing of Components
Assembly of Alternator
Testing Alternator
Precautions
Alternator Nomenclature
Alternator Service Test Specifications
Checking Alternator Belt Tension
Alternator System - 90 A m p Ford
Description of Alternator
Precautions
Checking Alternator System O n Aircraft
L'isual Inspection
Ammeter Prove-Out Test
Battery Supply Voltage Test
Voltage Output No-Load Test
Voltage Output Load Test
Alternator Bench Test Procedures
Rectifier Ground a n d Positive Diode Test
Stator Ground and Kegative Diode Test
Field Circuit Open o r Ground Test
24
- Cont./Effec.
Page - 1
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-30 1 / 30 1T
MAINTENANCE MANUAL
-
CHAPTER 24 ELECTRICAL POWER (cont.)
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION
SUBJECT
SUBJECT
GRID
NO.
EFFECTIVITY
D.C. GENERATIOX
Alternator System - 90 Amp Ford
Overhaul of Alternator Ford
Disassembly Procedure
Cleaning and Inspection
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
Diode Testing
Assembly Procedure
Alternator Belt Tension
Battery
Servicing Battery
Removal and Installation of Battery
Testing Battery
Charging Batterq
Battery Box Corrosion Prevention
Voltage Regulator
Checking Voltage Regulator
Overvoltage Relay
C h e c k ~ n gOvervoltage Relay
-
E X T E R S A L POWER
Operation of External Power Receptacle
ELECTRICAL SYSTEM L O A D DISTRIBUTIOK
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE M A N U A L
GENERAL.
This chapter contains instructions for correcting difficulties which may arise in the operation of the
electrical system. I t includes a general description and function of each part of the system along with test and
adjustments of the various components.
DESCRIPTIOK AND OPERATIOR.
The electrical system is a 14-volt, direct current, single wire, negative ground system. All electrical
equipment is grounded to the metal structure of the airplane, therefore, the structure takes the place of the
second wire. A 12-volt battery is incorporated in the system to furnish power for starting and as a reserve
power source in case of alternator failure. The battery and alternator are both connected to the bus bar. from
which all electrical equipment is powered. with the exception of the starter which receives its power from the
load side of the battery. The master switch controls the battery relay and field circuit. The master switch must
be on before any electrical equipment will operate. The airplane can be equipped with standard navigation
lights. rotating beacon and one landing light located in the nose cowl.
Troubles peculiar t o the electrical system are listed in Chart 2401 along with their probable causes and
suggested remedies. The wiring diagrams included at the end of this section will give physical breakdou n of the
different electrical circuits used in this airplane.
After the trouble has been corrected. check the entire electrical system for security and operation of its
components.
-- WARNING
-
A 11 checks and adjustments oj the alternator and/or its components
should be made with the engine stopped. Therefore, to complete
some checks or adjustments, it will be necessary to remove these
units from the airplane and place on a test stand.
24-02-00
Page 24-01
Issued: Januar) 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (A1 TERN ATOR)
I
I
Trouble
Cause
1
I-
Remedy
-
Zero output indicated on
ammeter regardless of R P M
(refer to alternator system
Open field circuit.
-
With master turned on,
check for battery voltage from
airplane's main buss through
entire field circuit to alternator field terminal. Measure
voltage from ground (-) to
the following points (+) in sequence: buss bar, output circuit breaker (60A). field circuit breaker (5A). field terminals of master switch. voltage
regulator and alternator field
terminal.
Interruption of voltage
through any of these points
isolates the faulty component
or wire which must be replaced. (See wiring schematic.)
Open output circuit
With master switch turned
on, check for battery voltage
from airplane's main buss
through entire output circuit
t o alternator battery post.
Measure voltage from
ground (-) to the following
points (+) in sequence: buss bar.
output circuit breaker.
ammeter, and alternator batt e q post.
Interruption of voltage
through any of these points
isolates the faulty component or wire which must be
replaced. (See wiring schematic, Chapter 9 1 .)
Open circuit in alternator
output will usually burn out
the ALT annunciator lamp
and the 50 ohm resistor.
Check the 5A inline fuse.
24-02-00
Page 24-02
Issued: Jnnuar! 2, 1980
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont)
Trouble
Zero output ~ndicatedon
ammeter regardless of RPM
(refer to alternator system
test procedure) (cont)
Cause
Open field winding in alternator.
Remedy
Disconnect field terminal of
alternator from field wiring
and check for continuity
from field terminal to ground
with ohmmeter (20- 100
ohms) depending on brush
contact resistance.
-- CA UTION
-
Turn magneto switch to off
before turning prop.
(Pull propeller s l o w ~ lb~
~
hand turning alternator rotor
through 360' of trat el.)
If resistance is high. check
brushes for spring tenslon
and excessive wear and replace if necessan.. If brushes
are okay and field reads
open, replace alternator.
Output ind~catedon ammeter does not meet mlnimum talues spec~f~ed
in alternator system test proced ure
Fault! voltage regulator.
S t a n engine. turn on load
(ref. alternator test procedure). set throttle at 2300
RPM. Check voltage at buss
bar (convenient check point.
remove cigar lighter and
check from center contact
(+) to ground (-). Voltage
should be 13.5-volts rnlnimum. If voltage is below t h ~ s
value, replace regulator.
24-02-00
Page 24-03
Issutd: January 2, 1980
.
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont)
Trouble
Output indicated on ammeter does not meet minimum values specified in alternator system test procedure. (cont)
Field circuit breaker
trips.
Cause
Remedy
High resistance connections in field or output
circuit.
Check visually for loose binding posts at the various junction points in system. alternator battery post. lugs on
ammeter, connections at voltage regulator. circuit breaker.
etc. (See wiring schematic.
Chapter 9 1 .) Examine
crimped terminal ends for
signs of deterioration at
crimp or strands of broken
wire at crimp. Tighten any
loose binding posts or replace bad wire terminals.
Open rectifier.
If any of the six rectifiers
pressed into the rear bell
housing of the alternator
open up internally. it will result in a definite limitation
on the current that can be
drawn from the alternator.
After having checked the
previous causes of low output it can be assumed that a
faulty rectifier exists.
See paragraph titled Inspection and Testing of
Components.
Short circuit in field
circuit.
Disconnect field wiring at
terminal of alternator. Turn
on master switch. If breaker
continues to trip. proceed to
disconnect each leg of field
circuit. working from the alternator towards the circuit
breaker until breaker can be
reset and will hold. Replace
component or wire which
was isolated as defective. (See
wiring schematic, Chapter
91.)
Page 24-04
Issued: Januar! 2, 1980
PIPER AIRCRAFT
PA-32-307 /301T
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ALTERKATOR) (cont)
Trouble
Field circuit breaker
trips. (cont)
Cause
S h o n circuit in field
winding of alternator.
Remedy
Disconnect field wiring at
terminal of alternator. Turn
on master switch. Reset
breaker and if breaker fails
t o retrip, this isolates short
circuit t o field of alternator
itself. Check brush holders
for shorting against frame. If
there are n o obvious signs of
a physical shon circuit'at field
terminal or brush holder. replace alternator. (Kote: intermittent shon circuit.)
Internal short circuiting of
the field can occur at various
positions of the rotor. therefore. reconnect field. reset
breaker, pull propeller slowl!.
by hand turning alternator
rotor through 360' of tra\.el.
Observe circuit breaker for
signs of tripping.
- CA UTIOA' Turn magneto switch to off
bejore turning propell&.
Ammeter indicates 60 amps
at 1400 R P M and above.
A L T annunciator light on.
Short to ground in alrernator output wiring.
Check condition of tenon
insulators on feet of diode
heat sink. When the mounting screws are overtorqued.
they can cut through insulators causing a short-toground. Check other wiring
for chafing. etc.
Battery installed with reversed polarit!..
Battery charged backwards.
Remove battery and reinstall
with correct polarit!,.
-
24-02-00
Page 24-05
Issued: Januar! 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont)
-
Trouble
Battery installed with reversed polarity. (cont)
Cause
Battery charged backwards.
Remedy
Remove battery. Connect
load such as landing light
lamp or similar load and discharge battery. Recharge
with correct polarity and test
each cell for signs of damage
due to reversed charging.
-NOTE
-
This type of condition can
only occur in a case where a
discharged battery has been
removed from the airplane
and put on a charger with the
polarity reversed. This reversal in polarity cannot
occur in the airplane due to
any fault in the alternator
system.
Excess~veammeter fluctuation.
Excessive resistance in
field circuit.
Check all connections and
wire terminals in field circuit for deterioration such as
loose binding posts. broken
wire strands at terminals. etc.
Tighten all connections and
replace faulty terminals.
High field circuit
resistance.
If problem persists, jump
across terminals of the following components one at a
time until the faulty unit is
isolated.
a. Field 5 amp (alternator)
circuit protector.
b. Alternator half of master
switch.
c. Overvoltage relay.
Defective voltage
regulator.
Replace voltage regulator.
d
Page 2 4 0 6 .
Issued: January 2, 1980
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
-
CHART 2402. TROUBLESHOOTING (BATTERY)
Trouble
Remedy
Cause
Battery worn out.
Replace battery.
Charging rate not
set right.
Reset.
Standing too long.
Remove and recharge battery if left in unused airplane
three weeks or more.
Equipment left on accidentally.
Remove and recharge
Impurities in electrolyte.
Replace.
Short circuit (ground) in
wiring.
Check wiring.
Broken cell partitions.
Replace.
Overcharge due to level of
electrolyte being below
top of plates.
Maintain electrolyte.
Sulfation due to disuse.
Replace.
Impurities in electrolyte.
Replace batteq .
Low charging rate.
Adjust voltage regulator.
Holddown bracket loose.
Replace battery and t~ghten.
Frozen battery.
Replace.
Compound on top of battery melts.
Charging rate too high.
Reduce charging rate by adjusting voltage regulator or
replace transistor~zedregulator.
Electrolyte runs out
of vent plugs.
Too much water added to
battery and charging rate
too high.
Drain and keep at proper
level and adjust voltage regulator.
Discharged battery.
Battery llfe 1s short.
Cracked cell jars.
i
24-02-00
Page 2 4 0 7
Issued: Januarj 2, 1980
1H4
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CHART 2402. TROUBLESHOOTING (BATTERY) (cont)
Trouble
Cause
i
Remedy
Spillage from overfilling.
Use care in adding water.
Vent lines leaking or clogged .
Repair or clean.
Charging rate too high.
Adjust voltage regulator.
Discharged battery.
Replace.
Water added and battery not
charged immediately.
Always recharge batter! for
112 hour following addit~on
of water in freezing weather.
Battery polanty reversed.
Connected backwards o n
charger.
Battery should be slowl! d ~ s charged completely and then
charged correctly and tested
Batteq consumes
water.
Charging rate too high (if
in all cells).
Correct charging rate.
Cracked jar (one cell
Replace battery.
Excess~vecorrosion ins~de
container.
Battery freezes.
excessive
Page 24-08
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
a
D . C . GENER.4TIOS.
I
ALTERNATOR SYSTE3I
- PRESTOLITE.
DESCRIPTIOS OF ALTERNATOR. (Refer to Figure 24-1.)
The principal components of the alternator a r e the brush holder assembly, the slip ring end head. the
rectifiers. the stator. the rotor and the drive end head.
1. The brush a n d holder assembly contains two brushes. two brush springs. a brush holder a n d
insulator. O n e brush is connected to a terminal stud and is insulated from ground. The other brush is
connected t o ground through the brush holder. The brush and holder assembly can easil! be remo\-ed for
inspection o r brush replacement purposes.
2. The slip ring end head provides the mounting for the rectifiers and rectifier mounting plate. output
and auxiliar! termlnal studs. and the brush a n d holder assembly. The slip ring end head contains a roller
bearing and outer race assembly and a grease seal.
3. The rectifiers used in these units are rated at 150 peak inverse voltage ( P . I . V . ) minimum for transient
1.oltage protection. Three positive rectifiers are mounted in the rectifier mounting plate while the three
negatl\,e rectifiers are mounted in the slip ring end head. Each pair of rectifiers is connected t o a stator lead 1t 11h
high temperature solder. The stator leads are anchored to the rectifier mounting plate with epos! cement for
v i b r a t ~ o nprotection.
4. The stator contains a special lead which is connected t o the center of the three phase wind~ngs.The
stator has been treated with a speclal epoxy varnish for high temperature resistance.
5 . The rotor contains the slip ring end bearing inner race and spacer on the slip ring end of the shaft. The
rotor u - i n d ~ n gand uinding leads have been specially treated with a high temperature epoxy cement to pro\ ide
\.ibration and temperature resistance characteristics. High temperature solder is used t o secure the ~ ~ n d i n p
leads to the slip rings.
6. The d r i i e end head supports a sealed. prelubricated ball bearing in which the dri\e end of the rotor
shalt rotates.
!
I
EFFECTI\'ITI.: PRESTOLITE
24-31-01
Page 24-09
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32-301 /30 1 T
MAINTENANCE MANUAL
I
1240
Cf
I
1 BRUSH HOLDER ASSEMBLY
2 SLIP RING END HEAD
3 RECTlFlERS
4 STATOR
5 ROTOR
6 DRIVE END HEAD
Figure 24- 1. Exploded View of Alternator
- Prestolite
2812
w
A l l i g a t o r Clips
w
3
3
3
3
3
3
3
(8) 8A Landing Lights
60- Ampere A l t e r n a t o r
Figure 24-2. Lamp-Bank Load
I
EFFECTI\'IT1.: PRESTOLITE
Page 24-10
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
CHECKING ALTERNATOR SYSTEM.
With all electrical equipment off (except master switch) the ammeter will indicate the amount of charging
current demanded by the battery. This amount will vary, depending on the percentage of charge in the battery
at the time. As the battery becomes charged, the amount of current displayed on the ammeter will reduce t o
approximately two amperes. The amount of current shown on the ammeter will tell immediately whether or
not the alternator system is operating normally, if the following principles are kept in mind.
-- NOTE
-
The amount o j current shown on the awunder is the l d i n amperes
that is demanded by the ektrical s y s t m from the ohemator. As a
check, takejor exmnple a condition where the battery is d h a d i t a g
10 amperes charging current, then switch on the W i n g Ught. Note
the value in amperes placarded on the circuit breaker panel jor the
landing light circuit breaker (10 amps) und mu&Qly this by 80
percent, you will anive at a current of 8 amperes. This is the
approximate current drawn by the light. Therrfore, when the light is
switched on, there will be an increase of current from 10 to 18
amperes displayed on the ammeter. As eash unit o j electrical
equipment is switched on, the current will odd up and the total,
including the battery, will appear on the awuneter.
Using the example that the airplane's maximum continuous load with all equipment on is approximately 48
amperes for the 60 ampere alternator. This approximate 48 ampere value, plus approximately two amperes for
a fully charged battery. will appear continuously under these flight conditions. If the ammeter reading were to
go much below this value. under the aforementioned conditions. trouble with the alternator system would be
indicated and corrective action should be taken by switching off the least essential equipment.
The following test procedure could be helpful in locating faulty components:
1 . Ascertain that the airplane is positioned so that the prop blast will not interfere with other operations
going on near by. Stan engine and set throttle for 1000 t o 1200 RPM.
2. Switch on the following loads and observe the ammeter output increase as indicated.
A . Rotating beacon 3 t o 6 amps.
B. Kavigation and instrument lights (bright position) 4 t o 6 amps.
C. Landing light - 7 t o 9 amps.
If alternator does not meet above indications. refer t o troubleshooting chart. Follow troubleshooting
procedure outlined on the chart in a step by step fashion checking each cause and isolation procedure under a
given trouble before proceeding to the next step.
On airplanes without night-flying equipment, load required by test can be simulated by connecting a
lamp-bank load consisting of 8 landing lights wired in parallel from main bus (+) to airframe ground (-). (Refer
to Figure 24-2) or 3-ohm. 100-watt resistors.
-
-
-- NOTE
-
On air-conditioned aircrajl,jull a&ernatoroutput on ground must
bt limited to not more than 10 minutes. Rejer to Pilot's Operating
Handbook.
I
EFFECTIF'ITI': PRESTOLITE
24-31-02
Page 24-1 1
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE MANUAL
SERVICE PROCEDURES.
Since the alternator and regulator are designed for use on only one polarity system. the foIIowlng
precautions must be observed when testing or servicing the electrical system. Failure to observe these
precautions will result in serious damage to the electrical equipment.
1. Disconnect the battery before connecting or disconnecting test instruments (except voltmeter) or
before removing or replacing any unit or wiring. Accidental grounding or shoning a t the regulator. alternator.
ammeter or accessories, will cause severe damage to the units andlor wiring.
2. The alternator must not be operated on open circuit with the rotor winding energized.
3. D o not attempt to polarize the alternator. No polarization is required. Any attempt to d o so may
result in damage to the alternator, regulator or circuits.
4. Grounding of the alternator output terminal may damage the alternator a n d / o r circuit and
components.
5. Reversed battery connections may damage the rectifiers, wiring or other components of the charging
system. Battery polarity should be checked with a voltmeter before connecting the battery. Most aircraft are
negative ground.
6. If a booster battery or fast charger is used, its polarity must be connected correctly to prevent damage
to the, electrical system components.
OVERHAUL O F ALTERNATOR.
When repairing the alternator. complete disassembly may not be required. In some cases it will onl! be
necessary to perform those operations which are required to effect the repair. However. in this section. the
complete overhaul is covered step-by-step to provide detailed information on each operation. In actual s e n Ice
practice. these operations may be used as required.
DISASSEMBLY OF ALTERNATOR.
1'. Remove the two Kumber 10-24 screws holding the brush holder assembly in the slip ring end head.
Remove the brush and holder assembly from the end head.
2. Remove the safety wire from the through bolts. Hold the pulley with a strap wrench and remove the
pulley nut. The pulley must be removed with a puller. Remove the fan, woodruff key and spacer from the shaft.
3. Remove the four through bolts and tap the drive end head lightly to separate the drive end head and
rotor. as a unit. from the stator and slip ring end head.
4. Remove the nuts. lock washers. flat washers and insulators from the output and auxilian. terminal
studs. Note carefully the correct assembly of the insulator washers and bushings. Using the special tools shown
in Figure 24-4. support the end head and press out the three negative rectifiers. The end head can now be
separated from the stator assembly.
. 5. To remove the slip ring end bearing and grease seal, it will be necessary to have a hook type or impact
type bearing puller as shown in Figure 24-3. Do not remove the bearing unless replacement is necessan.
-NOTE The inner race o j the
ring end k a h g &pressed onto the rotor
shoft. When tuarimg rrplacemmt is ncessory, always rrplocc the
complete b-karing assmbly, t t E M i n g the inner race.
I
EFFECTIVITY: PRESTOLITE
P ~ g 24-12
t
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
1
Figure 24-3. Removal of Slip Ring End Bearing
Figure 24-4. Removal of Rectifier
Figure 24-5. Removal of Drive End Head
Figure 24-6. Removal of End Head Bearing
EFFECTIVITY: PRESTOLITE
24-31-05
Page 24-13
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
.
RHEOSTAT
BATTERY
1
Figure 24-7. Testing Rotor for Ground
1
Figure 24-8. Testing Rotor for Shorts
6. T o remove the drive end head from the rotor shaft. usea puller that grips on the bearing retainer plate
as shown in Figure 24-5. Do not attempt to remove by supporting the end head and pressing on the shaft, as
this may result in distortion of the end head or stripping of the retainer plate screws. Remove the three retainer
plate screws and press the bearing out of the end head. (Refer to Figure 24-6.)
INSPECTION AND TESTING OF COMPONENTS.
Upon completion of the disassembly, all pans should be cleaned and visually inspected for cracks. wear or
distonion and any signs of overheating or mechanical interference.
I . Rotor: The rotor should be tested for grounded or shorted windings. The ground test can be made
with test probes. connected in series with a 1 I&volt test lamp, an ohmmeter or any type of continuity tester.
(Refer to Figure 24-7.) There must not be any continuity between the slip rings and the rotor shaft or poles. To
test for shorted turns in the rotor winding. connect a voltmeter, ammeter and rheostat as shown in Figure 24-8.
or use an ohmmeter. Rotor current draw and resistance arc listed in the Alternator Service Test Specifications
paragraph. Excessive current draw or a low ohmmeter reading indicates shorted windings. No current draw or
a n infinite ohmmeter reading would indicate an open winding.
IEFFECTIVITY: PRESTOLITE
-
Page 24-14
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2. Rectifiers: A diode rectifier tester will detect and pinpoint open or shorted rectifiers without going
through the operation of disconnecting the stator leads. However. if a tester is not available. test probes and a
KO. 57 bulb. connected in series with a 12-volt battery, can be used in the following manner. Touch one test
probe to a rectifier heat sink and the other test probe t o a lead from one of the rectifiers in that heat sink. Then
reverse the position of the leads. The test bulb should light in one direction and not light in the other direction.
If the test bulb lights in both directions, one or more of the rectifiers in that heat sink is shorted. To pinpoint the
defective rectifier, the stator leads must be disconnected and the above test repeated on each rectifier. Open
rectifiers can only be detected. when using the test bulb. by disconnecting the stator leads. The test bulb will fail
to light in either direction if the rectifier is open.
3. Stator: The stator can be tested for open or grounded windings with a 12-volt test bulb, described in
the rectifier section. or an ohmmeter, in the following manner. Separate the stator from the slip ring end head
just far enough to insert a fold of rags or blocks of wood. In other words, insulate the stator from the end head.
To test for grounded windings, touch one test bulb or ohmmeter probe t o the auxiliary terminal or any stator
lead, and the other test bulb or ohmmeter probe to the stator frame. If the test bulb lights, or the ohmmeter
indicates continuity, the stator is grounded. T o test for open windings, connect one test probe to the auxiliary
terminal or the stator winding center connection and touch each of the three stator leads. The test bulb must
light, or the ohmmeter must show continuity. Due to the low resistance in the stator windings. shorted
windings are almost impossible to locate. However, shorted stator windings will usually cause the alternator to
"growl" or be noisy during operation and will usually show some signs of overheating. If all other electrical
checks are normal and alternator fails to supply its rated output, the stator should be replaced to determine
whether or not it is the faulty component.
4. Bearings and Seals: Whenever the alternator is overhauled, new bearings and oil or grease seals are
recommended. even though the bearings and seals appear to be in good condition. A faulty seal can cause an
alternator to fail within a very short period of time.
ASSEMBLY OF ALTERNATOR.
I . Press the ball bearing into the drive end head using a flat block approximately two inch square so that
the pressure is exerted on the outer race of the bearing. Install the retainer plate. With the snap ring and
retainer cup in place on the rotor shaft. usea tool that fits over the shaft and against the inner bearing race, and
press until the inner bearing race is against the snap ring retainer cup. (Refer to Figure 24-9.)
2. Carefully install the rectifiers in the slip ring end head or rectifier mounting plate by supporting the
unit and using the special tools illustrated in Figure 24-10.
-
CA UTION
-
Use an arbor press, do not hmnmcr. Reconnect the stator letads to
the rectmers. Whensoldering these connections, use pliers as a heat
- d mon the &ad between the solderjoint and the r e w e r . Too much
heat will dawwge the rutflers.
3. Reassemble the rectifier mounting plate studs and insulators, making sure they are in the correct
order. (Refer to Figure 24-1 1.)
4. After the slip ring end head is completely assembled, the stator and rectifier leads must be secured to
the rectifier mounting plate with epoxy. Make sure the stator leads are positioned so that they d o not interfere
with the rotor.
5. Install the slip ring end bearing and oil seal. Make sure the lip of the oil seal is toward the bearing.
Stake the seal in place. Correct assembly of bearing, seal, inner race and spacer as shown in Figure 24- 12.
a
I
EFFECTIVITY: PRESTOLITE
24-31-07
Page 24-15
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 24-9. Installation of Bearing
Figure 24-10. Installation of Rectifier
-
INSULATOR
RECTIFIER MOUNTING PLATE
, +- y
TERMINAL STUD
U
OUT PUT (+)
TERMINAL
AUXILIARY
TERMINAL
Figure 24- 1 1. Terminal Assembly
- Prestolite
EFFECTIVITY: PRESTOLITE
-
Page 24-16
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
3a s
.
,*
370
SEAL - INSTALL SEAL WITH
LIP TOWARD BEARING
JUMPER WIRE
INNER RACE
SPACER
C - - - - - - -
I
---.---------J
T EST VOLTMETER
A
Figure 24-12. Slip Ring End Bearing Assembly
Figure 24- 13. Testing Alternator
6. Assemble the alternator and install the through bolts. Spin the rotor t o make sure there is no
mechanical interference. Torque the through bolts t o 30 t o 35 inch-pounds. Safety wire should be installed
after the unit has been bench tested for output. Install spacer. woodruff key, fan, pulley, lock washer and nut.
Torque the nut to 35 foot-pounds. using a strap wrench to hold the pulley.
7. Install the brush and holder assembly and retaining screws. Spin the rotor and check for interference
between the brush holder and rotor. Check between the field terminal and ground with an ohmmeter. The
ohmmeter must indicate the amount of rotor resistance listed. (Refer t o C h a n 2403. Alternator
Specifications.)
TESTING ALTERNATOR.
1. Wiring connections for bench testing the alternator are shown in Figure 24- 13. Refer t o the individual
specification C h a n 2403 for output test figures. Adjust the carbon pile if necessary, to obtain the specified
voltage.
2. After bench testing the alternator, install the safety wire and install the alternator on the engine.
-
NOTE
-
Ahvoys rejer t o the ohernator wiring d i a g r m (rder to Ekctricol
Schemtic Index, Chapter 91) when inrtaUing the olllernotor or
testing t k o&emator.
I EFFECTIVITY: PRESTOLITE
24-31-08
Page 24-17
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-30 1/ 30 1T
MAINTENANCE M A N U A L
373
END
VIEW
Y M VIEW
Figure 24-14. Brush Installation
Figure 24-1 5. Internal Wiring Diagram
PRECAUTIOKS.
The following precautions are to be observed when testing or servicing the electrical system.
I . Disconnect the battery before connecting or disconnecting test instruments, except voltmeter, or
before removing or replacing any unit or wiring. Accidental grounding or shorting a t the regulator, alternator.
ammeter or accessories, will cause severe damage to the units and/or wiring.
2. The output lead must not be removed from the alternator while the rotor winding is energzed and the
alternator is operating.
3. Do not attempt to polarize the alternator. No polarization is required. Any attempt to d o so may
result in damage to the alternator, regulator or circuits.
4. Grounding of the alternator output terminal may damage the alternator a n d / o r circuit and
components.
5 . Reversed battery connections may damage the rectifiers, wiring or other components of the charging
system. Batter) polarity should be checked with a voltmeter before connecting the battery. This aircraft is
negative ground.
6. If a booster battery or fast charger is used, its polarity must be connected correctly t o prevent damage
to the electncal system components.
EFFECTIYITY: PRESTOLITE
Page
24-31-09
24-18
Revised: February 19, 1982
a
-
PIPER AIRCRAFT
'
PA-32-301/301T
MAINTENANCE MANUAL
•
ALTERSATOR \O>lE\CLATL'RE.
I . B e a r ~ n g sThese
.
unlts ha\.e a sealed ball bearing at the drive end a n d a tho-piece roller bearlng at the
slip ring end. The Inner race is pressed o n t o the rotor shaft and the rest of the bearing is in the slip ring end head.
M'hen the unit 1s assembled. the inner race aligns with the bearing. When the bearing is replaced. the n e u inncr
race must be installed on the rotor shaft.
2. Lubrication: The slip ring end bearing should be lubricated whenever the alternator is disassembled.
The b e a r ~ n gshould be thoroughly cleaned and repacked with Shell Alvania No. 2 or an equi\.alent bearing
lubricant. The ca\.it!. behind the bearing should be packed one-third to one-half full with the same l u b r ~ c a n t .
3. Brushes: These units have a separate brush holder. assembly that is installed after the alternator has
been assembled. The brush holder has a small hole that intersects the brush cavities. Use a pin or a piece of
ire. as sh0u.n in Figure 24-14 to hold the brushes in the holder during assembly. Remo1.e the pin after the
brush holder retain~ngscreus have been tightened. Make a continuity check to be sure the brushes are seated
against the slip rings.
4. Dri\.e Pulle!.: Torque the dri\,e pulley retaining nut 10.35 foot-pounds (minimum) t o 40 foot-pounds
(maximum).
ALTERS.L\TOR SERL'ICE T E S T S P E C I F I C A T I O X S .
I
C H . 4 R T 2403. A L T E R S A T O R S P E C l F l C A T l O S S ( P R E S T O L I T E )
Alternator 31odel
ALY 6422
Rated Output
60 amperes
-
--
f
-.-
1
-
Ground Polar~t!
3egatiLe
Rotallon
BI-D~rect~onal
w
2w
J
---5
Rotor ('0' to ?-OfF )
Current Drau
--x
Ou!put Test ( 7 0 - to 80'
\ 011s
Amperes Output
Alternator R P J I
I
E F F E C T I L I T I : PRESTOLITE
1
2.4 to 4.0 amps @ 12.0-\olts
3.5 to 5.0 ohms
Resistance
)
14.0
13.0
2000 min.
14.0
47.0
4000 mln
24-31-1 1
Page 24- 19
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
CHECKlSG ALTERSATOR BELT TENSIOK.
If properl! installed. tensioned a n d checked periodically. the alrernator drive belt w i l l gi\.e \ e r >
satisfactory s e n i c e . However. a n improperly tensioned belt will wear rapidly a n d may slip and reduce
alternator output. Consequently. a belt should be checked for proper tension at the time 11 is installed. agaln
a f t e r 25 hours operation and each 100 hours thereafter.
- NOTE For aircraft with air conditioning installed, rejer to Chapter 21, jor
replacement and adjustment of compressor drive belt.
There a r e two satisfactory methods of checking alternator belt tension; however. the first method
described wfill be found preferable by most maintenance personnel because it is technically simple and requires
little time for accomplishment.
1 . Torque Method: This method of checking belt tension consists of measuring torque required to s l ~ p
the belt at the small pulley and is accomplished a s follows:
A . Apply a torque indicating wrench to the nut that attaches the pulley t o the alternatorand turn it
In a clockwise direction. 0bsert.e the torque shown on the wrench a t the instant the p u l l e ~slips.
.
B. Check the torque indicated in Step A with torque specified in the following Chart 2.104. .Ad!usr
belt tension accordingl!..
2. Deflection Method: Belt tension may be checked by measuring the amount of deflection caubed b! a
predetermined amount of tension. This is accomplished in the following manner:
A. Attach the hook of a small spring-scale t o the belt a t the approximate mid-point between the rear
gear support a n d the alternator.
B. Pull on the scale until a reading of 14 pounds is obtained. (10 pounds for used belts.)
C. hleasure the distance the belt has moved with the 10 or 14 pound load applied. The distance
(deflection) should be 5 16 inch. If less than 5 16 inch. the belt is too tight.
3. Cpon completion of alternator belt tension adjustment. torque the alternator pi\-ot bolts 2 2 5 - 2 5 5
inc h-pounds.
I
C H A R T 2403. A L T E R S A T O R BELT TENSION
b'ldth of Belt
3 8 ~nch
3 8 ~nch
I 2 ~nch
I 2 ~nch
Cond~t~on
New
Used
Neu
Used
-NOTE
-
PRESTOLITE
Torque lnd~catedat
alternator pulle!
1 l to
7 to
13 to
9 to
13 ft.-lbs.
9 ft.-lbs
15 ft -Ibs
l l ft -1bs.
-
The higher tension specified jor a new belt is to compensatefor the
initial stretch that takes place as soon as it is operated. These higher
tension values should not be applied to belts which previously have
been used.
I
1 EFFECTl\'ITI': PRESTOLITE
Page 21-20
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
A L T E R S A T O R SYSTEM (90 AMP F O R D )
I
D E S C R I P T I O S O F A L T E R S A T O R . (Refer t o Figure 24-16)
The pr~ncipalcomponents of the alternator are the Front Housing. Fan and Pulley. Rear Housing and
Terminal ldentif~cation.Stator Core a n d Coil Assembly. Rotor Core and Coil. Brushesand Holder Assembl!
and Rectifier Assembl!..
I . The front housing is a die-cast aluminum part which meets design requirements for a light-weight.
non-magnetic material. This casting incorporates the bosses used t o attach the assembly to its mounting
bracket. I t also pro\.ides the supporting surface for the rotor shaft front bearing and vendor identification data
stamped into the front, housing.
The fan and pulle? are attached t o t h e rotor shaft with a nut and lock-washer. The forward end of the shaft
is threaded to accept the nut.
2. The rear housing is also a die-cast aluminum part which supports the rotor shaft rear bearing and
pro\ ides mounting bosses for the rectifier a s s e m b l ~ The
.
housing contains the various electrical connections
and openlngs for cooling airflou. (Refer to Figure 24-17 for Terminal identification.)
3. The stator core and coil assembl!. consists of a number of steel stampings ri\.eted together to form the
stator core H hich contalns 36 equall! spaced v e n ~ c a slots
l
t o accomodate the stator coil bindings. (Reier t o
F ~ g u r e24- 18.)
3 . The rotor core and coil assembl! consists of the rotor shaft. two slip rings. two rotor haI\ej and the
coil assembl!. The shaft I S supported at each end b!, bearings. The front bearing (ball-type) is a slip f ~ on
t the
shaft and 1s retained In the front h o u s ~ n gu ~ t ha retainer. The rear bearing(need1e-type) is pressed into the rear
h o u s ~ n g The
.
s l ~ prlngs. core and coil assembl! are press-fitted t o the shaft with a rotor half en\,eloping each
end of the c o ~ l .
The rotor core and coil assembl! turns inside the stator core and coil assembly with a very narrou a1r gap
betueen the t u o assernbl~es.thus de\-eloping maxlmum magneto induction.
5 . The brush and holder assembl! 1s installed in a cai.it! inside the rear housing. The brushes ride the
surfaces of the s l ~ prlngs on the rotor shaft under spring pressure a n d transmit field current through t h e ~ r
c ~ r c u i tt o ground. One brush o r f ~ e l dterminal is. therefore. insulated from the housing.
6. The rectifier assembly is located betueen the stator a n d the inside surface of the rear h o u s ~ n g .
.4ttachment to the housing I S made b!. means of mounting studs that protrude from the positi\e and negatl\e
diode plates cheat sinks). The positi\.e plate is insulated from the housing. and the negati\,e plate is grounded to
the housing through the studs. The rectifier a s s e m b l has a printed circuit board spaced away from the heat
s ~ n h s (Refer
.
to F ~ g u r e24-19.)
The stator u ~ n d i n gleads are soldered to integral terminals on the back of the circuit board. The stator
phase t o p I S attached to the Insulated stator terminal. The heat sinks are attached to the circuit board 1~1th
Insulated spacers and roll pins maintaining the necessary separation between the two assemblies. The diodes
themselies are exposed. The rectifier assembly has three diode plates connected t o an A C potential. Each o f
the three plates 1s connected t o one of the three stator leads. Two steel conductor plates o r "bus bars". one
positi\e and the other negati\e. circle the diodes beginning at the "BAT" and "GND" terminal studs. The bus
bars act as termlnatlon points for collecting the D C current from the terminal wire of each diode. One p o s i t i ~ e
and one negatiie d ~ o d eis soldered t o each of three stamped aluminum plates to form the plate and diode
assembl~es.The alurn~numplates ser\.e as heat sinks to cool the diodes by providing increased surface area to
the air flou through \en1 slots in the rear housing to the fan a t the front of the alternator.
One plate and diode assembl! is connected t o each of the three leads t o form the full wave bridge rectifier.
Dlode t e r m ~ n a lwires are connected t o the bus bars by means of a flexible connector wire. One diode is
connected to the p o s i t i ~ ebus bar. and the other diode. o n each plate. is connected to the grounded or negati\e
bus bar. (Refer to F ~ g u r e24-20.)
I
I
I
Ii
I
E F F E C T I I ' I T I ' : FORD
24-32-01
Page 24-21
Added: August 23. 1982
I
I
Figure 24-16. Alternator Exploded View
- Ford
Figure 24-17. Rear View and Terminal Identification
EFFECTI\'ITI': F O R D
Page 24-22
Added: August 23. 1982
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
C201
TO DIODES
TO DIODES
CONNECTION
TO DIODES
TO DIODES
Figure 24- 18. Stator Core Windings
C213
BAllERY TERMINAL
POSITIVE OR INSULATED DIODE PLATE
c GROUND TERMINAL
NEGATIVE OR GROUND DIODE PLATE
Figure 24- 19. Rectifier Assembly
EFFECTI\'TI': FORD
24-32-01
Page 24-23
Added: August 23, 1982
,
I
PIPER AIRCRAFT
PA-32-30 11301T
MAINTENANCE MANUAL
.
30@7
DETAIL B
DIODES
DETAIL A
STATOR
PHASE
PHASE
PHASE
-
1 AJ
-
3
-1
3
-
Phase. - 3
--
-v-*,3-'-.....
. . i
1
-
FLD
DETAIL C
ROTOR
Figure 24-20. Internal Relationships of Alternator Components
EFFECTl\'ITY: FORD
Page 24-24
Added: 'August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
PRECAUTIOSS.
As a preface to testing the charging system, it cannot be overemphasized how important it is to observe
the precautions listed. Considerable time and expense can be saved by following these simple rules.
1. Always disconnect the battery ground cable before disconnecting wiring or components of system.
2. Avoid contacting alternator output terminal (BAT)a s it is directly connected to the batter? bus
voltage anytime battery cables are connected and "BAT" portion of master switch is ON.
3. Never connect the battery ground cable until all system wiring connections and components are
complete.
4. When adjusting belt tension, always apply force near pulley of the alternator to avoid damage to
stator and rectifier, or use a I '/en O.E.. Wrench on the adjustment lug of the alternator case casting.
5. Never attempt t o polarize the alternator. Polarizing is not applicable to alternator and could damage
the regulator.
6. Observe polarity when installing a battery in aircraft. Reverse polarity will destroy the diodes in
alternator.
7. Always connect a booster battery in parallel, negative to negative. positive t o positive.
8. Before disconnecting a booster battery, reduce engine speed to idle, operate taxi light. This will
prevent voltage surge that could destroy small light bulbs.
9. Disconnect the battery ground cable before connecting a charger to the battery.
-
CHECKING ALTERNATOR SYSTEM Oh' AIRCRAFT.
VISUAL INSPECTION.
Prior to testing. a visual inspection of components of charging system should be performed. What
appears to be an authentic charging system problem, can in some instances be traced to some of the
discrepancies out-lined here that are relatively simple to correct.
I. Proper belt tension if alternator pulley wheel can be slipped on belt by hand -the belt is too loose or
glazed replace or tighten belt per specification.
2 . Specific gravity of battery is 1.275 - fully charged battery.
3. Clean and tighten battery posts and cable clamps.
4. Clean and tighten wiring connection at alternator.
5 . Clean and tighten wiring connections at regulator.
-
-
Because o j additional transistorized electrical components being
incorporated, a simplified voltmeter testing procedure is prejerred
to prevent damge to other components. Follow test procedures as
arranged jor systematic problem solving approach.
AMMETER PROVE-OUT TEST.
Place the "BAT' portion of master switch in the ON position (engine not running). Switch the landing
light switch ON. Ammeter should show discharge. If the ammeter needle does not move, check wiring
connections at ammeter are tight and 'clean, or ammeter is defective - replace ammeter.
EFFECTI\'ITY: FORD
24-32-05
Page 24-25
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
BATTERY SVPPLY VOLTAGE TEST.
If aircraft ammeter shows discharge with engine running perform this test before checking alternator
voltage output. The test will \,erifythat the battery voltage is being supplied t o the regulator. Alternator cannot
provide output unless field voltage is supplied.
1. Disconnect connector at voltage regulator.
2. Connect \,oltmeter positive lead t o pin I of disconnected plug(B lead of regulator) and nega1ii.e lead
t o aircraft structure.
3. Turn "Master Switch" ON. (Bat and Alt). Voltmeter should read battery voltage. If voltage is not
present. check continuity of wiring harness from regulator plug to alternator circuit breaker. Assure that
alternator regulator circuit breaker is closed and not defective.
VOLTAGE OUTPUT NO-LOAD TEST.
This test as well as the following voltage output load test. should be performed whene\-er a n
"o\,ercharging" o r "undercharging" condition is suspected.
Visual check as pre\iousl!, outlined. should be made and engine should be at normal operating
temperature.
I. Connect voltmeter positi\,e lead t o positive b a t t e ~terminal and negative lead to negatile batter!
terminal. Record Reading.
2. Assure that all switches and lights are off no load condition.
3. Start engine and slouly increase speed t o approximately 1500 R P M .
4. Check voltmeter reading. The voltage should increase. but not more than 4 volts abo\e \oltage
recorded in step 1 .
5 . I f the voltage does nor increase. or if the increase is within the 4 volt limit. proceed to VOLTAGE
O U T P U T L O A D TEST.
6 . If \.oltage increase exceeds 4 volts. stop engine and isolate "overvoltage" problem as follous:
A. Disconnect regulator plug from regulator and repeat the test with plug disconnected.
B. Voltmeter should show no increase in voltage a s excitation voltage t o alternator is cut-off Replace regulator.
C. If \olta_ee increases u,ith the regulator plug disconnected. excitation voltage is being supplied t o
alternator field b!, short circuitr!.. Isolate and check continuity of wiring harness. repair or replace.
-
VOLTAGE OUTPUT LOAD TEST.
This test is. in effect. a continuation of the preceding No-Load Test.although this portion applies more to
a condition of "undercharge" than "overcharge".
I . Reconnect regulator plug.
2. i'oltmeter connected to negative and positive post of battery - record voltage reading.
3. Turn off all accessory switches - open circuit breakers where switches d o not control circuits.
4. Start the engine. Apply a load by turning on the landing light.
5. Sloul!. increase engine speed to 1500 R P M .
6. Voltage reading step 2 should increase a minimum of 0.5 volt above previous reading.
7. Turn off landing light and shut down engine.
8. If voltage fails to increase above 0.5 volt - open alternator portion of master switch. An "under\.oltagea condition exists. Proceed as follows t o isolate problem.
EFFECTI\'lTI': FORD
24-32-08
Page 24-26
Added: August 23. 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
A. Disconnect the regulator plug and install a jumper from the positive terminal of battery to pin 2
(F pin of regulator plug).
-- CA UTION
-
Operate engine not more than 2 minutes with jumper installed,
damage to components o j electrical system could occur.
-
B. Start engine -turn on alternator switch -apply electrical load (turn on landing light). Slowly
increase engine speed to determine that voltage of step 2 increases. Stop RPM increase when voltage measures
.O volt.
C. Voltage reading at battery should increase above previous reading 0.5 volts or more.
D. Turn off landing light - turn off alternator switch shut down engine.
If the increase in voltage reading is still below 0.5 volt, the problem is in wiring harness or alternator.
E. Remove the jumper end from the voltage regulator plug and connect it t o the "FLD"pin of the
alternator (plug removed). This eliminates the wiring harness t o prove the alternator.
F. Leave alternator regulator plug disconnected.
G. Start engine -turn on alternator switch -apply electrical load -(turn on taxi and landing llghts).
Slowly increase engine speed to determine that voltage of step 2 increases. Stop RPM increase when voltage
measures .O volts. Observe 2 minute operation caution.
If the voltage increase is now above 0.5 volt, fault is wiring harness. Repair or remove and replace harness.
If the voltage increase is still below 0.5 volt, the fault is in alternator and should be removed from the
aircraft for bench test.
-
a
ALTERNATOR BENCH TEST PROCEDURES.
When on-aircraft-testing determines an alternator malfunction. The following bench tests should be
performed on the removed alternator.
An ohmmeter is the only equipment required for bench check. Ohmmeter should be "zeroed" when each
resistance setting is selected. "Zeroing" is accomplished by touching the ohmmeter probes together and
adjusting zero knob to align meter on full scale reading.
RECTIFIER GROUND A N D POSITIVE DIODE TEST.
-- CA UTION
-
DO NOT use digital ohmmeterfor this test, because it willgivejalse
indications.
1. Set the ohmmeter selector switch to resistance scale 10 and zero the meter.
2. Attach one ohmmeter lead to "BAT* terminal and the other t o the "STA" terminal. Check for a
reading of 60 ohms, it should be obtained in one direction and an infinite (no needle movement) in other
direction (reverse leads t o check opposite direction).
3. A reading of 60 ohms or less in both directions indicates:
A. A defective positive diode.
B. A grounded positive diode plate.
C. A grounded alternator "BAT' terminal.
4. Infinite reading (no needle movement) in both directions indicates an open "STA" (Stator) terminal
connection.
EFFECTIVITY: FORD
24-32- 10
Page 24-27
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
OHMMETER
ALTERNATOR
C
F ~ g u r e24-21. Rectifier Ground and Positive Diode Test
COO3
ALTERNATOR
I
i
Figure 24-22. Stator Ground and Negative Diode Test
EFFECTIVITY: FORD
Page 24-28
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 1301T
. MAINTENANCE MANUAL
--
STATOR G R O U S D A N D NEGATIVE D I O D E TEST.
-- CAUTION
-
D O NOT use digital ohmmeter for this test, because it willgivefalse
indications.
I. Set the ohmmeter selector switch on resistance scale 10 and zero meter.
2. Connect one lead t o the "STA" terminal and the other lead to the " G R D terminal. A reading of
approximately 60 ohms should be obtained in one direction and a n infinite reading (no needle movement) in
the other direction. Reverse leads and check in opposite direction.
3. A reading of 60 ohms or less in both directions indicates:
A . A defective negative diode.
B. A grounded positive dipde plate.
C. A grounded alternator " B A T ' terminal.
D. A grounded "STA" terminal.
E A grounded stator winding (laminations grounded or windings grounded to front or rear
housing).
4. lnf~nitereadings (no needle movement) indicates an open "STA" (Stator) terminal connection.
FIELD CIRCUIT OPEN O R G R O U N D TEST.
1. Set ohmmeter selector switch to resistance scale 1 and zero meter.
2. Connect one lead to the "FLD" terminal and the other lead to the " G R D terminal.
3. Spin the pulley and note ohmmeter reading. Meter should read between 4 and 200 ohms and fluctuate
while rotor is turning.
4. A reading lower than 4 ohms indicates:
A . A grounded positive brush.
B. A grounded field terminal.
C. A defective rotor.
5 . A reading higher than 200 ohms indicates:
A. Worn out or hung brushes.
B. An open brush lead.
C. A defective rotor.
a
EFFECTI\'ITI': FORD
24-32- I2
Page 21-29
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE M A N U A L
Figure 24-23. Field Circuit Open or Ground Test
THIS SPACE INTENTIONALLY LEFT BLANK
EFFECTIVITY: FORD
Page 24-30
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
OVERHAUL O F ALTERNATOR -- FORD.
DISASSEMBLY PROCEDURE.
1. Scribe a mark across the stator and front and rear housings to facilitate alignment during reassembly.
2. Separate the front housing and rotor from rcar housing by removing the four thru bolts between
housings and remove rear housing.
3. Remove the retainer nuts and insulators from the "BAT" terminal and "GRD" terminals.
4. It is not necessary to disassemble the complete rcar housing to replace the brush assembly only.
Unsolder the stator lead, remove two screws securing the brush holder assembly. (Refer to the Assembly
Section for installation procedure.)
5. Remove 4 retainer bolts from rectifier assembly and 2 retainer bolts from brush assembly, remove 1
screw from radio suppression capacitor lead and remove stator, rectifier assembly and brush assembly from
rear housing.
6. If the rear shaft bearing require replacement support the housing on the inner bearing boss and press
the bearing from the housing.
7. If the rectif~eris to be replaced, or, if the stator and diodes arc to be bench checked, separate the
rectifier from the stator by unsoldering the terminal connections of stator windings and rectifier assembly.
(Use 100 Watt soldering iron to prevent excessive heat buildup.)
8. Unsolder stator terminal from rectifier.
c10a
HOUSING THRU
BOLT ( 4 ) PLACES
SCRIBE
UNE
Figure 24-24. Alternator Housing Disassembly
EFFECTI\.ITY: FORD
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
czoo
STATOR SOLDER
CONNECTION
(3) PLACES
SUPPRESSION
RECTIFIER RETAINE
BOLT (4) PLACES
STATOR BRUSH
CONNECTION
REAR HOUSING
REAR BEARING
b
Figure 24-25. Rear Housing Components
EFFECTIVITY: F O R D
Page 24-32
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
9. Separate the rotor. fan and pulley from the front housing by removing the hex nut. A special tool
similar to Figure 24-26 is required t o remove nut. Remove pulley, fan and rotor.
SOCKET WRENCH
16 BOX WRENCH
Figure 24-26. Front Housing Disassembly
10 R e m o ~ ethe front bearing from the housing by removing the bearing retainer screws. The bearianp rs
normall! a s l ~ p - f ~howe\zer.
t.
~f stuck. support houslng and press bearing from the housing.
C210
ROTOR
RONT BEARING
FRONT HOUSING
RETAINER
(2) PLACES
Figure 24-27. Front Housing Components
24-32-14
Page 24-33
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CLEANING A S D INSPECTIOIV.
1. Clean the rotor. stator and bearings with a clean cloth. D o not clean these pans with solvent.
2. Rotate the front bearing on the drive end of the rotor shaft. Check for any scraping noise. looseness.
or roughness. Look for excessive lubricant leakage. If any of the conditions exist, replace bearing.
3. Inspect the rotor shaft rear bearing surface for roughness o r severe chatter marks. Replace the rotor
assembly if the shaft is not smooth.
4. Place the rear bearing on the slip-ring end of the rotor shaft and rotate the bearing. Make the same
check for noise. looseness, o r roughness as was made for the front bearing. lnspect the rollers and cage for
damage. Replace the bearing if these conditions exist, o r if the lubricant is lost or contaminated.
5 . Check the pulley and fan for excessive looseness on the rotor shaft. Replace any pulley or fan that is
loose or bent out of shape.
6 . Check both the front and rear housings for cracks. particularly in the webbed areas and at the
mounting ear. Replace damaged or cracked housings.
7. Check all wire loads on both the stator and rotor assemblies for loose or broken soldered connections
and for burned insulation. Resolder poor connections. Replace p a n s that show signs of burned insulation.
8. Check the slip-rings (brush contacts) for nicks and surface roughness. Nicks and scratches ma! be
removed by turning down the slip rings.
-- CAUTION
-
Do nor turn slip-rings beyonda minimum diameter of l.22inches. I j
the rings are badly damaged, replace the rotor assembly.
9. Replace brush assembly if brushes are worn beyond 5,' 16 inch minimum length.
EFFECTI\'ITY: FORD
Page 24-34
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
ROTOR C O N T I S ~ I T YTEST.
I . Separate the front housing and rotor assembly from rear housing by removing four housing-thru
bolts and separate rear and front housing. The springs and brushes are not retained by brush holder when
hous~ngsare separated.
2. Set the ohmmeter selector switch on resistance scale 1 and zero meter.
3. Touch one lead of ohmmeter to each segment of the slip ring. The meter should read 3 to 5 % ohms.
4. Readings higher than 5% ohms indicate a damaged solder connection a t the slip rings or a broken
wire.
5 . Readings lower than 3 ohms indicate a shorted wire o r slip ring.
6. Replace the rotor if repairs cannot be made.
I
OHMMETER
Figure 24-28. Rotor Continuity Test
EFFECTIVITY: FORD
24-32- 16
Page 24-35
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
ROTOR GROL'ND TEST.
1. Set the ohmmeter selector switch on 1000 scale and zero the meter.
2. Touch one lead to the rotor shaft and the other lead to first slip ring then to the other. The ohmmeter
should read infinity (no needle movement) in both checks.
3. If the meter shows a reading (needle moves) a short t o ground exists. Check the soldered connections
at the slip rings t o make sure they are secure and grounding against the rotor shaft, or that excess solder is not
grounding the rotor coil.
4. Replace the rotor if repairs cannot be made.
If both the "Rotor Continuity Test" and the "Rotor Ground Test"
prove satisfactory, and the "Field Circuit Open or Ground Test"
showed trouble, the brushes are the cause.
OHMMETER
Figure 24-29. Rotor Ground Test
EFFECTIVIT)': F O R D
Page 24-36
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
STATOR CONTINUITY TEST.
Using a 100 watt soldering iron. disconnect the three stator wires from diode assembly. and remove
stator from rear housing.
2. Set the ohmmeter selector switch on resistance scale I and zero the meter.
3 Connect ohmmeter leads alternately between all three sets of leads. Meter readings should be equal
between any pair of stator leads.
4. If unequal readings are obtained. the stator winding is open. Check wiring junction. If breaks are
found repair and recheck. If unequal readings still exist, replace the stator.
1.
Figure 24-30. Stator Continuitv Test
EFFECTI\'IT1': FORD
24-32-18
Page 24-37
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
STATOR G R O U S D TEST.
1. Set ohmmeter selector switch on resistance scale 1000 and zero the meter.
2. Connect one meter lead t o bare metal portion of stator core and other lead alternately to each of the
stator leads. The ohmmeter should read infinity (no needle movement). Be sure lead is making good contact
with stator core surface.
3. If meter shows any reading (needle moves) the stator is grounded and must be replaced.
Figure 24-31 Stator Ground Test
Page 24-38
Added: August 23. 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
a
D I O D E TESTISG.
Stator must be disconnected from rectifier assembly to perform this test. Rectifier shown removed for
clarity.
I. Set the ohmmeter selector on resistance scale 10 and zero the meter.
2. Test the negative diodes by connecting one ohmmeter lead to " G R D post terminal on rectifier and
connect other lead to each stator lead connection of rectifier momentarily. Reverse ohmmeter leads and check
in opposite direction. Meter must show continuity in one direction and infinity (no needle movement) in other
direction.
3. Test the positive diodes by connecting one ohmmeter lead to the "BAT' terminal on.rectifier and
other lead t o each stator lead connection of rectifier momentarily. Reverse ohmmeter leads and check in the
opposite direction. Meter must show continuity in one direction and infinity (no needle movement) in other
direction.
4. If continiuty is observed in both directions, the diode(s) is shorted.
5. If no continuity is observed in both directions, the diode(s) is open.
6. Replace the rectifier assembly if open or shoned diodes are found.
Cl89
OHMMETER
DIODE PLATES
Figure 24-32. Diode Testing
E F f ECTI\'lTY: FORD
24-32-20
Page 24-39
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
ASSEMBLY PROCEDURE.
1. Clean all pans with a lint free cloth.
2. Position the front bearing in the front housing and install the bearing retainer screws.
3. lnstall spacer on rotor shaft and slide rotor shaft through housing and bearing.
4. lnstall spacer. fan. pulley, flat washer,lock washer and nut. Tighten the nut to 60- 100ft.-lbs. A special
tool similar to Figure 24-33 is required t o torque nut.
3066
SPACER
ROTOR
FRONT BEARING
RETAINER
(2) PLACES
FRONT HOUSIN
OROUE WRENCH
1 5 / 1 6 INCH BOX END
I
Figure 24-33. Front Housing Assembly
EFFECTIVITY: FORD
Page 24-40
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-331/301T
MAINTENANCE MANUAL
5. If the rear bearing was removed, press a new bearing into place from inside the housing. Apply
pressure to the outer race only. Install dust cover over bearing end of housing.
6. Install radio suppressor capacitor in rear housing and install retainer screw.
7. Install springsand brushesinto brush holder. Install short length of.040 wirethrough brush holderto
retain brushes in place. Wire should be long enough to extend through hole in housing for removal after
housings are assembled.
8. Install two retainer screws in brush assembly and housing. Hold down on brush assembly while
tightening screws, to prevent breaking brush assembly attachment brackets.
9. Install insulator on "BAT" post of rectifier assembly and install insulators (2) in place in the rear
housing for mounting bolts in positive "BAT" side of rectifier.
10. Carefully install rectifier and stator into rear housing, assure insulators are in place. Install "BAT"
post insulator and nut and "GRD" post retainer nut, finger tight.
11. Install the 4 rectifier retainer bolts (check insulators on positive side) finger tight, and install
suppression capacitor lead to rectifier and tighten screw.
12. Tighten "BAT" and "GRD" retainer nuts then 4 rectifier retainer bolts.
13. If stator has been separated from the rectifier,install the 3 stator winding leads to rectifier posts and
solder with 100 watt iron (to prevent overheating of connection) and resin core solder. Solder the stator
terminal lead to diode assembly.
14. Position the front and rear housingstogether, align scribe marks on housingsand stator, and install
four thru-bolts in housings. Alternatelytighten each thru-bolt around alternator until a preliminarytorque of
15 to 25 inch-pounds is reached for each bolt. Final torque each thru-bolt alternately around the alternator
until each bolt is torqued 45 to 60 inch-pounds.
15. Spin pulley to ensure that alternator is free of binding or noise.
16. Pull retainer wire from brush assembly and seal hole in housing with EP-711 Coast Pro-Seal
Compton. California or equivalent.
C207
NOTE
REAR BEARING
SUPPRESSION
CAPACITOR
NEW BRUSH ASSEMBLY
COMES WITH RETAINER
PIN INSTALLED
STATOR TERMINAL
CONNECTION TO
RECTIFIER
SEALJOINTOF BRUS
ASSEMBLY AND HOUSING
WITH SEALER EP-711
COASTAL PRO-SEAL
COMPTON. CALIFORNIA
OR EQUIVALENT
Figure 24-34. Rear Housing Bearing and Brush Assembly Installation
EFFECTIVITY: FORD
24-32-21
Page 24-41
1I14
1114
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
c211
BAlTERY TERMINAL INSULATOR
REAR HOUSING
RECTIFIER INSULATORS
STATOR
Figure 24-35. Rear Housing Components
BRUSH ASSEMBLY
RETAINER WIRE
Figure 24-36. Housings Assembly
EFFECTIYITY: FORD
Page 24-42
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
BOLT AN5-7A
WASHER AN960-516
C677
520074-06-06
E 160-190 IN LBS
IRE TO ARM USING
5-C32 LOCK WIRE)
WASHER 62833-90
(UNDER BOLT HEAD.COAT
WASHER WITH ZINC CHROMATE
PRIOR TO INSTALLATION I
WASHER (2) AN960-716
NUT MS20365-720C
SPACER 38747-3
TORQUE BOLT 450-500
IN LBS AFlER BELT
TENSION HAS BEEN ESTABLISHED
F i g u r e 24-37. A l t e r n a t o r installation
- Ford
- ALTERNATOR BELT TENSION.
L o o s e n b o t t o m m o u n t i n g b o l t a n d b e l t a d j u s t i n g bolt. A d j u s t t h e b e l t t e n s i o n to o b t a i n 90-100 Ibs. s p a n
t e n s i o n . A f t e r t e n s i o n is set a n d u p p e r bolt safetied. t i g h t e n l o w e r mounting bolt 450 to 500 I b . - i n . T h e r e s h o u l d
b e n o e n d p l a ) in a l t e r n a t o r m o u n t . Add thin washers b e t w e e n a l t e r n a t o r a n d mount to r e m o v e e n d pla!..
-- CAUTION
-
Whenever a new belt is installed, beb tension should be re-checked
within IS minutes of operation. If tension folk below SO Ibs. retension to 70 Ibs.
When tightening the alternator belt, apply pressure by using a 1%
inch open end wrench on adjusting lug o/ alternator.
a
EFFECTIVITY: FORD
24-32-22
Page 24-43
Added: August 23, 1982
PIPER AIRCRAFT
PA-32-301
/301T
MAINTENANCE MANUAL
BATTERY.
SERVICING BATTERY.
The batten is located under the floor of the forward baggage companment on the PA-32-30 I and in the
tailcone behind the aft cabin bulkhead on the PA-32-301T. It is enclosed in a box with a vent system and a
drain. The vents allow fresh air to enter the box and draw off fumes that may accumulate due to the charg~ng
process of the battery. The drain is capped off from the bottom of the fuselage and should be opened
occasionally t o drain any accumulation of liquid or during cleaningof the box. The battery should be checked
for fluid level, but must not be filled above the baffle plates. A hydrometer check should be performed to
determine the percent of charge in the battery. All connections must be clean and tight. If the battery is not u p
to normal charge. recharge starting with a charging rate of four amperes and fininishing with two. A fast
charge is not recommended. Access to the battery is through the external access panel on the right side of the
fuselage.
REMOF'AL A N D INSTALLATION O F BATTERY.
1 . Remove the external access panel and the floor panel located in the forward baggage companment on
the PA-32-301 and gain access through the aft baggage compartment on the PA-32-301T.
2. Cut the safety wire and remove the wing nuts that secure the battery box cover.
3. Disconnect the battery cables.
Always remove the ground a b l e first and instau last to prevent
occidental short circuiting or arcing.
Lift the batter?. from the box.
5 . T h e battery may be installed in reverse order of removal.
4.
-- CAUTION
-
Do not install battery with reverse polarity. Connect ground to
negative terminal of battery.
TESTIKG BATTERY.
The specific pravit\- check method is listed in Chart 2405. If the alternator output is know to be correct.
the question of battery capability can be more accurately determined with a load type tester.
Page 24-44
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32.301 /301T
MAINTENANCE MANUAL
CHARGING BATTERY.
If the battery is not up to normal charge. remove the battery and recharge stanin! with a charging rate o f 4
amps and finishing with 2 amps. A fast charge is not recommended.
CHART 2405. HYDROMETER READING A N D BAlTERY CHARGE PERCENT
I
Hydrometer Reading
Percent of Charge
1280
1250
1220
1190
1160
1 130 or below
100
75
50
25
Very little useful capacity
discharged
L
BATTERY BOX CORROSION PREVENTION.
The battery should be checked for spilled electrolyte o r corrosion at least each 50 hour inspection or at
least every 30 days, whichever comes first. Should this be found in the box, on the terminals or around the
battery, the battery should be removed and both the box and battery cleaned by the following procedure:
1. Remove the box drain cap from the under side of the fuselage and drain off any electrolyte that ma!:
have overflowed into the box.
- CAUTION Do not aUow soda solution to enter battery.
2. Clean the battery and the box. Corrosion effects may be neutralized byapplyinga solution of baking
soda and water mixed to a consistency of thin cream. The application of this mixture should be applied until all
bubbling action has ceased.
3. Rinse the battery and box with clean water and dry.
4. Place the cap over the battery box drain.
5. Reinstall the battery.
I VOLTAGE REGULATOR.
CHECKING VOLTAGE REGULATOR.
The regulator is a fully transistorized unit in which all of the components are encapsulated in epoxy.
which makes field repair of the unit impractical, and if it does not meet the specifications, it must be replaced.
The regulator may be tested by the following procedure:
1. Be sure that the battery is fully charged and in good condition.
24-34-0 1
Page 24-45
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
2. Check the alternator according to the manufacturer's instructions, to determine if it is functioning
properly. This test must be done with the regulator out of the circuit. After completing this test. reconnect the
regulator into the circuit.
3. Use a good quality accurate voltmeter with at least a IS volt scale.
4. Connect the positive voltmeter lead t o the red wire at the regulator harness connector, or terminal
block. Connect the negative voltmeter lead t o the regulator housing. (Note) D o not connect the voltmeter
across the battery, because the regulator is designed t o compensate for resistance contained within the wiring
harness.
5. With the alternator turning at sufficient rpm t o produce a half load condition, or approximately 25
amperes output, the voltmeter should read between 13.6 and 14.3 volts. The ambient temperatures
surrounding the voltage regulator should be between 5O0F to 100°F while this test is being made.
6. The voltage regulator heat sink, or case, is the ground connection for the electronic circuit. Therefore.
if this unit is tested on the bench, it is most important that a wire, No. 14, be connected between the regulator
case and the alternator. If the regulator does not regulate between 13.6 and 14.4 volts, one of the follow~ng
conditions may exist:
A. Regulates, but out of specification. The regulator is out of calibration and must be replaced.
-- NOTE
-
The 68804-3 (Lamar) regulator has a block ground wire that must
have a low resistance connection t o the ground system. It is
adjustable and should be set to 14.0 volts.
B. The voltmeter continues to read battery voltage.
( I ) Poor or open connections within the wiring harness.
(2) The regulator is "open."
C. Voltage continues to rise.
( 1) Regulator housing not grounded.
( 2 ) Regulator shorted, must be replaced.
These are some of the things to look for in case of failure:
A. Poor or loose connections.
B. Poor ground on the regulator housing.
C. Shorted alternator windings.
D. A grounded yellow wire. (This will cause instantaneous failure.)
E. Disconnecting the regulator while the circuit energized.
F. Open circuit operation of the alternator. (The battery disconnected.)
Proper installation of solderless terminah on aluminum cables
presents special difficulty in that each individualstrand is insulated
by an oxide coating. This oxide coating must &broken down in the
crimping process and some method employed t o prevent its
reforming (usually a corrosion preventative jell material). For this
reason Piper does Not recommend the repair or replacement of
loose, corroded or other unsat&factory conditions of soIderless
terminah on aluminum cables. .When an unsat@factory condition is
discovered, Piper recommends that the complete cable assembly be
replaced. Should this not be practical, it is permissible t o replace the
oluminum cable assembly with a copper cable assembly, using a
copper cable two sizes smaller. Example: A t - 1 aluminum cable
replaced with AN-3 copper cable.
Page 24-46
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
OVERVOLTACE RELAY.
CHECKING OVERVOLTACE RELAY.
The relay may be tested with the use of a good quality, accurate voltmeter, with a scale of at least 20-volts
and a su~tablepower supply, with an output of at least 20-volts, or sufficient batteries with a voltage divider to
regulate voltage. The test equipment may be connected by the following procedure:
1. B+ is connected to "Bat" of the overvoltage control.
2. B- is connected to the frame of the overvoltage control.
3. Be sure both connections are secure, and connected to a clean, bright surface.
4. Connect the positive lead of the voltmeter t o the "Bat" terminal of the overvoltage control.
5. Connect the negative lead of the voltmeter t o the frame of the overvoltage control.
6. The overvoltage control is set to operate between 16.2-volts to 17.3-volts. By adjusting the voltage. an
audible "click" may be heard when the relay operates.
7. If the overvoltage control does not operate between 16.2 and 17.3-volts, it must be replaced.
EXTERNAL POWER.
OPERATION O F EXTERNAL POWER RECEPTACLE.
The external power receptacle is located on the left side of the nose section just aft of theengine cowling on
the PA-32-301 and on the right side behind the aft cabin bulkhead on the PA-32-3OIT. When using external
power for starting or operation of any of the airplane's equipment,
the following. procedure
should be
.
.
followed:
Turn the master switch O F F and turn all electrical equipment OFF. Connect the R E D lead of the P E P kit
jumper cable to the POSITIVE 1'1 terminal of an external 12-volt batten and the BLACK lead to the
~EGATIVE
(-) terminal. Insert the plug of the jumper cable into the socket ldcated on the fuselage. h'ote that
when the plug is inserted, the electrical system is ON. Proceed with the normal starting technique.
After the engine has started. reduce power to the lowest possible RPM, to reduce sparking. and
disconnect the jumper cable from the aircraft. Turn the master switch ON and check the alternator ammeter
for an indication of output. DO NOT ATTEMPT FLIGHT I F THERE IS NO INDICATION O F
ALTERSATOR OUTPUT. If aircraft battery is weak, chargingcurrent will be high. DO NOT TAKE O F F
until charging current falls below 20 amps.
For a11 normal operations using the PEPjumper cables, the master
switch should be OFF, but it is possible to use the ships battery in
parallel by turning the master switch ON. This will give longer
cranking capabilities, but will not increase the amperage.
CA UTJON:Care should be exercised because i j the ships battery
has been depleted, the external power supply can be reduced to the
level of the shbs battery. This can be tested by turning the master
switch ON momentarily whik the starter is engaged. I j cranking
speed increases, the ships battery it at a higher level than the external
power supply.
24-41-00
Page 24-47
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/3OlT
MAINTENANCE MANUAL
When the engine is firing evenly. advance the throttle to 800 RPM. If oil pressure is not indicated within
thirty seconds. stop the engine and determine the trouble. In cold weather it will take a few seconds longer to
get an oil pressure indication. If the engine has failed to start, refer to the Lycoming Operating Handbook.
Engine Troubles and Their Remedies.
Starter manufacturers recommended that cranking periods be limited to thirty seconds with a two minute
rest between cranking periods. Longer cranking periods will shorten the life of the starter.
ELECTRICAL SYSTEM LOAD DISTRIBUTION.
CHART 2406. ELECTRICAL SYSTEM COMPONENT LOADS
Duty Cycle
Inter.
Cont .
X
X
X
X
X
X
X
X
X
X
X
X
X
Equipment
Anti-Collision Light
Grimes 40-0 101-XX- 12
Whelen WRML-I2
Whelen White Strobe
Position Lights
Landing Lights
Instrument Light(s)
Red Flood
Panel
Reading Light
Dome
Fuel Pump
Pulsating (Carb)
Engine Gauges
Elec. Turn & Bank
Pitot Heat
Cigar Lighter
Master Solenoid
Starter Solenoid
Autopilot (Avg)
Radio (See Mfg's Installation Manual)
Circuit
Breaker
Load
(Amps)
10
10
10
7
10
5
5
5
3.5
3.5
3.8
5.4
8.0
(Max)
1.O
2.4
5
0.6
10
5
5
I5
.5
Approx. 1.0
0.5
13.2
8.0
0.8
10.0
0.6
I5
5
Optional
X
- END -
Page 24-48
Issued: January 2, 1980
a
CHAPTER
EQUIPMENT/ FURNISHINGS
,
PIPER AIRCRAFT
PA-32301 1301T
MAINTENANCE MANUAL
-
CHAPTER 25 EQUIPMENT/FURNISHINGS
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTION
SUBJECT
25- 10-00
15- 1 1-00
25- 12-00
GRID
SUBJECT
FLIGHT COMPARTMEh'T
Rigging Instructions - Seat Back
Lock and Release
Shoulder Harness Inertia Reel Adjustment
RO.
EFFECTIVITY
1124
A 8-82
1124
1JI
-
25 Cont./Effec.
Page 1
Revised: August 11, 1983
-
~
1
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
A281
1. SCREW
2. SCREW
1. CLAMP
4 . CLAMP
I.BUSHING
6 . CLIBLE
7 . STOP ASSV.
STOPSHOULD BE LUBRICATED AND FREE
T O SWIVEL WITHOUT EXCtSSIVE PLAY
STRAIGHTEDGE
Figure 25- 1 . Seat Back Lock
I
FLIGHT COhlPARTMEh'T.
-
RIGGING 1h'STRL:CTIONS SEAT BACK LOCK A N D RELEASE. (Refer t o Figure 2 5 - 1 . )
1. Loosen screws and ascertain that clamps are in a relaxed condition. (Push-pull cable I S able to mn\c
u i t h ~ nthe clamps.)
2. Place a straightedge along the lower surface of bushing of the seat back release.
3. Adiust the push-pull cable by raising or lowering it until the lower surface of the stop assemhl!
parallel to the straightedge.
4 . Secure the push-pull cable in this position by tightening screws on clamps. The stop should be
lubricated and free to switel without excessive play.
t assembly
h
in a n engaged position t o check engagement. Rotate the 3eat
5 . Push on seat back ~ ~ stop
back release handle and check for d~sengagementof seat back.
I.
Page 25-01
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
SHOULDER HARNESS INERTIA REEL ADJUSTMENT.
1. Allow the harness to wind up on the reel as much as possible.
2. On the end of the reel. pry off the plastic cap over the sprhg, making sure the spring does not come out
of the plastic cap, and set cap aside.
3. Unwind the harness completely, then measure and mark the harness 24 inches from the reel center.
4. Wind the harness onto the reel until the 24 inch mark is reached. then hold reel and place cap with
spring over the reel shaft end.
5 . Aligning slot in shaft with spring tang, wind spring 6 turns 2 I / 2 turn and snap the plastic cover into
holes in reel end shaft.
6. Release harness and allowing it t o wind up, extend the harness a few times to check reel for smooth
operation.
7. With reel fully wound, hold with inertia mechanism end up and pry off plastic cap over mechanism
and set reel aside.
8, Install nut in plastic cap so that stud in cap is flush with nut surface. then reposition cap over reel end
and orientating properly. snap in place. Extend harness a few times to make sure action is correct.
- END -
25-1 2-00
Page 25-02
Revised: August 11, 1983
CHAPTER
FLIOHT CONTROLS
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
-
CHAPTER 27 FLIGHT CONTROLS
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION
SUBJECT
SUBJECT
GRID
NO.
EFFECTIVITY
GESERAL
Standard Procedures
Troubleshooting
CONTROL COLUMN ASSEMBLY
Removal of Control Column Assembly
lnstallation of Control Column Assembly
AILERON AND TAB
Aileron Control Cables
Remo\al of Aileron Control Cables
lnstallation of Aileron Control Cables
Aileron Bellcrank Assembly
Remokal of Aileron Bellcrank Assembly
lnstallation of Aileron Bellcrank Assembly
Rigging and Adjustment of Aileron Controls
Aileron Rudder Interconnect
Rigpng and Adjustment of Aileron, Rudder
l nterconnect
RUDDER AND TAB
Rudder Control Cables
Remo\al of Rudder Control Cables
lnstallat~onof Rudder Control Cables
Rigg~ngand Adjustment of Rudder Controls
Rudder Trim Controls
Remokal of Rudder Trim Controls
lnstallation of Rudder Trim Controls
Rlgging and Adjustment of Rudder Trim Controls
Rudder and Steering Pedal Assembly
Remoial of Rudder and Steering Pedal Assembly
lnstallation of Rudder and Steering Pedal Assembly
STABILATOR AKD TAB
Stabilator Control Cables
Remo\*alof Stabilator Control Cables
lnstallation of Stabilator Control Cables
27 - Cont./Effec.
Page 1
Revised: August 9. 1981
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
C H A P T E R 27 F L I G H T C O N T R O L S (cont)
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTIOX
SUBJECT
SUBJECT
GRID
K0 .
EFFECTII'ITI'
STABILATOR A S D T A B
R ippinp and Adjustment of Stabilator Controls
Stabilator Trim
Remoial of Stabilator Trim Assembly - Forward
l nstallation of Stabilator Trim Assembly - Forward
Remo\al of Stabilator Trim Controls - Aft
Installation of Stabilator Trim Controls - Aft
Rigging and Adjustment of Stabilator Trim
FLAPS
M'ing Flap Controls
Remo\al of Manually Operated Wing Flaps
Installation of Manually Operated Wing Flaps
Ripping and Adjustment of Manually Operated
Wing Flaps
Remo\al of Electricall! Operated Wing Flaps
Installation of Electricall! Operated Wing Flaps
Rigging and Adjustment of Electric Flaps
1 K23
ILI
I L3
I L3
S T A L L W A R K I S G H O R S A S D LIFT DETECTOR
Lift Detector
Remo\ al of Lift Detector
lns~allationof Lift Detector
Adjustment of Lift Detector
-
Page 2
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
I
The airplane is controlled in flight by the use of three primary control surfaces. consisting of ailerons.
stabilator and rudder. Operation of these controls is through the movement of the control column-tee bar
assembly and rudder pedals. O n the forward end of each control column is a sprocket assembly. A chain is
wrapped around the sprockets t o connect the right and left controls and then back to idler sprockets on the
column's tee bar. which in turn connect to the aileron primary control cables. T h e cables operate the aileron
bellcrank and push-pull rods. The stabilator is controlled by a cable connected t o the bottom of the tee bar
assembly and t o the top and bottom sides of the stabilator balance arm. Cables also connect the rudder pedals
with the rudder horn. Provisions for directional and longitudinal trim control is provided by an adjustable
trim mechanism for the stabilator and rudder. T h e stabilator trim is controlled by a wheel and drum mounted
on the floor tunnel between the front seats. Cables routed aft from the drum t o a screw assembly mounted
ab0k.e the stabilator attachment point. This screw assembly in turn moves the push rod which controls the
stabilator trim tab. The rudder trim is controlled by a knob and screw assembly attached t o the rudder pedal
assembly. An interconnect system is provided which consists of a spring loaded cable located in the fuselage
tunnel w,hich connects the aileron cable to the rudder cable. The flaps are mechanically operated on earl!
models and electricall! operated on 1985 models.
S T A S D A R D PROCEDURES.
The following tips ma!. be helpful where applicable in the individual control system procedures.
I . Turnbuckles must be assembled and adjusted in a manner that each terminal end is screwed an
approximatel!. equal distance into the barrel. During adjustment. the terminals must not be turned in a
manner which would put a permanent twist in the cable.
2 . After adjustment is completed. each turnbuckle must be checked. Not more than three terminal
threads shall be \-isible outside the barrel. Locking clips must be installed and checked for proper installation
b! tr\ ing t o remo\-e the clips using fingers onl),. Locking clips which have been installed and remoked must be
scrapped and new clips used.
3. Torque all nuts in the flight control surface rigging system in accordance with A C 43.13-1 A or to
torques specified within this manual text.
3. After completion of adjustment. each jam nut must be tightened securely and inspected.
5. O n push rods or rod ends provided with an inspection hole. the screw must be screwed in sufficientl!
far to pass the hole. This can be determined visually or feel. by insertinga piece of wire into the inspection hole.
I f no inspection hole is pro\.ided. a minimum of .375 of a n inch thread engagement must be maintained.
6 All cable rigging tensions given must be corrected to ambient temperature in the area where the
tension is being checked b!. using Chart 2702.
7. See Figure 27- 1 for the proper method of adjusting rod ends to prevent possibledamage and binding
of bearing surface in rod end. and all pulley guard pins installed.
TROVBLESHOOTISG.
Chart 2701 lists troubles peculiar to the flight controls along with their probable causes and suggested
remedies. When troubleshooting the flight controls. additional reference may be obtained from Chapters 55
and 57 on control surface balancing if required. After the trouble has been corrected. check the entire system
for security and operation.
27-02-00
Page 27-01
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)
Trouble
Cause
Remedy
AILERON COKTROL SYSTEM
Cable tension too low.
Adjust cable tension.
Linkage loose or worn.
or replace.
Check linkage and tighten
or replace.
Broken pulley.
Replace pullel.
Cables not in place on
pulleys.
Install cables correctly.
Check cable guards.
System not lubricated
properly.
Lubricate system.
Cable tension too high.
Adjust cable tension.
Control column horizontal
chain improperly adjusted.
Adjust chain tension.
Pulleys binding or rubbing.
Replace binding pulle) s
and lor provide clearance
between pulleys and
brackets.
Cables not in place on
pulleys.
Install cables correctl!.
Check cable guards.
Bent aileron and / o r hinge.
Repair or replace aileron
and / o r hinge.
Cables crossed or routed
incorrectl) .
Check routing of control
cables.
Control wheels not synchron~zed
Incorrect control column
rigging.
Rerig control column.
Control wheels not horizontal when a~leronsare
neutral
lncorrect rigging of aileron
system.
Rerig aileron system.
Lost motion between control wheel and aileron.
Res~stanceto control wheel
rotation.
b
27-02-00
Page 27-02
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
Trouble
Cause
I
Remedy
AILERON CONTROL SYSTEM (cont)
Aileron control rods not adjusted properly.
Adjust control rods.
Aileron bellcrank stops not
adjusted properly.
Adjust bellcrank stops.
Correct aileron travel cannot be obtained by adjusting bellcrank stops.
Incorrect rigging of aileron
cables. control wheel and
control rod.
Rerig controls.
Control wheel stops before
control surfaces reach full
travel.
Incorrect rigging between
control wheel and control
cables.
Rerig controls.
Incorrect aileron travel.
RUDDER COXTROL SYSTEM
Lost motlon between rudder pedals and rudder.
E x c e s s ~ ~resistance
e
to rudder pedal movement.
Cable tension too low.
Adjust cable tension.
Linkage loose or worn.
Check linkage and tighten
o r replace.
Broken pullel.
Replace pulley.
Bolts attaching rudder to
bellcran k are loose.
Tighten bellcrank bolts.
System not lubr~cated
properly.
Lubricate system.
Rudder pedal torque tube
bearing in need of lubrication.
Lubricate torque tube bearings.
Cable tension too high.
Adjust cable tension.
Pulleys binding or rubbing.
Replace binding pulleys and
o r provide clearance between pulleys and brackets.
27-02-00
Page 27-03
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
r
Trouble
I
Cause
I
Remedy
RUDDER CONTROL SYSTEM (cont)
Cables not in place on
pulleys.
Install cables correctly.
Check cable guards.
Cables crossed or routed
incorrectly.
Check routing of control
cables.
Rudder pedals not neutral
when rudder is streamlined.
Rudder cables incorrectly
rigged.
Rerig rudder cables.
Incorrect rudder travel.
Rudder bellcrank stop incorrectly adjusted.
Rerig bellcrank stops.
Nose wheel contacts stops
before rudder.
Rerig nose wheel stops.
Excessive resistance t o rudder pedal movement. (cont)
RUDDER TRIM CONTROL SYSTEM
Trim control knob moves
with excessive resistance.
System not lubricated
properly.
Lubricated system.
STABILATOR CONTROL SYSTEM
Lost motion between control wheel and stabilator.
Resistance to stabilator
control movement.
Cable tension too low.
Adjust cable tension.
Linkage loose or worn.
Check linkage and tighten
or replace.
Broken pulley.
Replace pulley.
Cables not in place on
pulleys.
Install cables correctl!.
System not lubricated
properly.
Lubricate system.
Cable tension too high.
Adjust cable tension.
Binding control column.
Adjust and rubricate.
Page 27-04
Revised: August 11, 1983
a
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
I
Trouble
Cause
STABILATOR CONTROL
Resistance to stabilator
control movement. (cont)
I
SYSTEM
Remedy
(cont)
Pulleys binding or rubbing.
Replace binding pulleys and
or provide clearance between pulleys and brackets.
Cables not in place on
pulleys.
Install cables correctly.
Cables crossed or routed
incorrectly.
Check routing of control
cables.
Bent stabilator hinge.
Repair or replace stabilator
hinge.
Incorrect stabilator travel.
Stabilator stops incorrectly
adjusted.
Adjust stop screws.
Correct stabilator travel
cannot be obtained by adjusting stops.
Stabilator cables incorrectly rigged.
Rerig stabilator cables.
STABILATOR TRIM COKTROL SYSTEM
FLOOR TRIM
Lost motion between trim
control wheel and trim tab.
Trim control wheel m o ~ e s
with excessive resistance.
Cable tension too low.
Adjust cable tension.
Cables not in place on
pulleys.
Install cables properly.
Broken pulley.
Replace pulley.
Linkage loose or worn.
Check linkage and tighten or
replace.
System not lubricated
properly.
Lubricate system.
Cable tension too high.
Adjust cable tension.
Pulleys binding or rubbing.
Replace binding pulleys.
Provide clearance between
pulleys and brackets.
27-02-00
Page 27-05
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
C H A R T 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont)
Trouble
I
I
Cause
STABILATOR TRIM CONTROL SYSTEM
FLOOR TRIM (cont)
Trim control wheel moves
with excessive resistance.
(cont)
Trim tab fails to reach full
travel.
Cables not in place on
pulleys.
Install cables properly.
Trim tab hinge binding.
Lubricate hinge. If necessan.
replace.
Cables crossed or routed
incorrectly.
Check routing of control
cables.
System incorrectly rigged.
Check and / o r adjust rigging.
Trim drum incorrectly
wrapped.
Trim indicator fails to indicate correct trim position.
Remedy
.
Trim indicator unit not adjusted properly.
Check and 1 or adjust rigging.
Adjust trim indicator.
FLAP COKTROL SYSTEM
Flaps fail to extend or
retract.
Control cable broken or
disconnected.
Replace or reconnect control cable.
Flaps not synchronized or
fail to move evenly when
retracted.
lncorrect rigging of system.
Adjust flaps.
Page 27-06
Revised: August 11,1983
a
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHART 2702. CABLE TEKSION VS. AMBIENT TEMPERATURE
110
l I0
too
C,
I
SUBTRACT
I
ADD
I
RIGGING LOAD CORRECTION, POUNDS
27-02-00
Page 27-07
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
b
a01
DAMAGE
HERE
DAMAGE
HERE
IWROPER TOOL (RESULTING IN LOCKED BALL)
a
A SPECIAL WRENCH M A Y BE
REQUIRED WITH A LONG THROAT
ONLY CORRECT METHOD
2
F~gure27-1. Rod End Installation Method
1512
27-02-00
Page 27-08
Revised: August 11, 1983
a
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
COSTROL COLI'MS ASSEMBLY.
I
I
,
REMOVAL OF CONTROL COLL'MN ASSEMBLY. (Refer t o Figure 27-2.)
I
I.
T o rem0t.e either control wheel with tube. the following procedure may be used:
A. Separate the control wheel tube from the flexible joint that is located on either side of the tee bar
assembl! by remo\,ing the nut. washer and bolt. Pull the tube from the flexible joint.
B. If remoiing the left control tube. slide the stop from the tube.
C. Should wires for the various Autopilot systems be installed in thecontrol tube. disconnect them
a t the quick disconnect terminals behind the instrument panel. Draw the wires back into the tube and back out
through the forward end of the tube.
D. Remote the control wheel assembly from the instrument panel.
2. The tee bar with assembled parts may be removed from the airplane by the following procedure:
A. Remo\.e the access panel t o the aft section of the fuselage.
B. Re1iet.e cable tension from thestabilatorcontrol cablesat one ofthe stabilator cable turnbuckles
in the aft section of the fuselage.
C . Relieve tension from the aileron control cables and chains a t the turnbuckle that connects thc
chains at the top of the tee bar.
D. Disconnect the control chains from the control cables where the chains and cables loin by
remixing the cotter pins. nuts. bolts and bushings.
E . If the control wheel assemblies ha\,e not been previously disconnected from the tee bar assembl!..
separate the control wheel tubes at the flexible joints by removing the nuts. washers and bolts.
F . Remote the tunnel plate just aft of the tee bar by laying back enough tunnel carpet t o rem0t.e the
plate attachment screus.
G . Remo\e the two aileron control cable pulleys attached t o the lower section of the tee bar b?
remot.ing the pulle! attachment bolt.
H. Disconnect the stabilator control cables from the lower end of the tee bar assembl!.
I . Disconnect the necessar! control cables. such a s the propeller pitch control. mixture control.
etc.. that kill allou the tee bar assembl!. to be remoted.
g
bolts with u,ashers and nuts w.hich are
.I. Remo1.e the tee bar assembl! by r e m o ~ , i n theattachment
through each side of the floor tunnel. and lifting it up and out through the right side of the cabin.
IYSTALLATION OF CONTROL COLUMN ASSEMBLY. (Refer t o Figure 27-2.)
The lee bar assembly may be installed in the airplane by the following procedure:
A . Suing the tee bar assembly into place from the right 'side of the cabin and secure with attachment
bolts. mashers and nuts inserted through each side of the floor tunnel.
B. Connect the stabilator control cables t o the lou.er end of the tee bar with bolt. washer. nut and
cotter pin. Allow the cable ends free t o rotate.
C. Place the aileron control,cables around the pulleys that attach t o the lower section of the tee bar:
position pulle!s and secure with bolt. washers and nut.
D. Install the control wheel per Step 2.
E. Place the control wheels in neutral (centered) position and install the aileron control chains on
the control u heel sprockets and idler cross-over sprockets. The turnbuckle must be centered betueen the t u o
control uheel sprockets.
F. Loosen the connecting bolts of the idler sprockets t o allow the chain t o fit snug around the
control wheel sprockets and o t e r the idler sprockets.
G . Connect the aileron control cables t o the ends of thechains with bolts. bushings. nutsand cotter
pins.
I.
27-05-02
Page 27-09
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
9.
2.
S.
4.
8.
6.
7.
8.
S.
10.
II.
-
12.
1).
14.
18.
I@.
8CROCKIT, R I @ W 1CONTROL WMECL
I L C I I 8 L I J01Ml
BOLT A S I T .
T U I I . CONTROL W M I C L
ConTIOL WMIEL (L a I 1
TURIDUCKLI
T I C BAR A88Y.
-*0"OI R
I
WASMIR. C O I T R O L WMCEL
C L A t I , COUTROL W M I C L
WA8*LR. COWTROL WMIEL
~CACLR.DTOC
8 C R O C I L T , L I I T CONTROL WMCEL
CNAlU, L E I 7 R O L L I R
I O L I R S ~ O C K L T ,A
TI
C I A l l , II.*T
ROLLtR
0. DOLT, DUINll.,
ZO.
21.
22.
ZS.
IUT
COTTII
PI*
N L L I T 8lABlLAl0l
C U L L I T 8 AILCRO*
CAULKS. A I L C I O I CONTROL
C M L C I . 8TADILATOI C M T I O L
Figure 27-2. Control Column Assembly
27-05-02
Page 27-10
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
H. Adiust the chain turnbuckle between the twocontrol wheel sprockets toallow thecontrol wheels
t o be neutral and obtain proper cable tension a s given in Figure 27-4. It may be necessan. in order t o have both
control m.heels neutral t o set the chain turnbuckle to neutralbe the wheels and then set cable tension mith the
turnbuckles located under the floor panel aft of the main spar. Before safetying the turnbuckle. check that
when the ailerons are neutral. the control wheels will be neutral and the chain turnbuckle centered. Also the
aileron bellcranks should contact their stops before the control wheel hits its stop. Maintain .030 t o .040
clearance between sprocket pin and adjustable stop bolts o n models having adjustable tee bar stops.
1. Set stabilator cable tension with the turnbuckle in the aft section of the fuselage. Check safet! of
all turnbuckles upon completion of adjustments.
J . Tighten the connecting bolts of the idler sprockets.
K . Install the floor tunnel plate and secure with screws. Fasten the tunnel carpet in place.
2 . Either control wheel assembly may be installed by the following procedure:
A. Insert the control wheel tube through the instrument panel.
9. Should wires for the various Autopilot systems need t o be installed in the control tube. route
them through the hole in the forward side of the tube a n d out of the small hole in the side. Position the rubber
grommet in the hole in the side of the tube.
C. O n the left control tube. install the stop.
D. Connect the control wheel tube t,o the flexible joint of the tee bar assembly. If the control cables
and, o r chains ha\.e not been remo\,ed o r loosened. place the ailerons in neutral and install the control tube on
the flexible joint t o allom the control wheel t o be neutral. Install bolt. washer and nut and tighten.
I
AILEROX A K D TAB.
I
A l L E R O S COSTROL CABLES.
The aileron control cablesare of standard 1 8 inch. 7 x 19(seven strandsof 19wires per strand)gaI\anbed
aircraft cord u hich has been dipped in a corrosion pre\,entativecompound. Depending on the installation. the
cable ma! h a t e swaged stud terminal ends. fork-end strap fitting and swaged ball t!,pe terminal ends. or a
combination of the t u o .
REhIOl'AL O F AILERON COKTROL CABLES. (Refer t o Figure 27-3.)
I . For the remolal o f an! of the control cables in the fuselage o r wings.first remove the floor panel that
is located direct]! aft of the main spar by removing the center seats. seat belt attachments and the screws
securing the panel. Lift the panel and remo\e from the airplane.
2. T o remote either the right o r left primary cables that are located in the fuselage. the follouing
procedure ma! be used:
.4. Remote the fuel selector knobs by loosening the set screws in each knob.
B . Remote the fuel selector knobs and cover assemblies by removing the knob set screwsand co\er
attachment screu 5 .
C. Remole the tunnel plate just aft of the tee bar by laying back enough tunnel carpet t o remo1.e the
plate attachment screbs.
D. Remole the forward heat duct from one side of the floor tunnel (preferably from the side from
which the cable is t o be removed) by removing the trim control wheel cover. the heater bafflesfrom the side of
the duct. the floor carpet and the duct attachment screws.
E. Separate the primar! control cable at the turnbuckle located in the floor opening aft of the main
spar.
27-1 1-01
Page 27-1 1
Revised: August 11. 1983
PIPER AIRCRAFT
MAINTENANCE MANUAL
! TURNBUCKLE. CONTROL CHAINS
2 . SPROCKET. CONTROL WHEEL
3 . SPROCKET. IDLER
4 . CHAIN. AILERON CONTROL
5 . B R A C K E T . PULLEY
6 . B E L L C R A N K . AILERON
1 . ROD. A I L E R O N C O N T R O L
8 . P U L L E V . TEE B A R
? . P U L L E V , F O R W A R D CLUSTER
1 0 . P U L L E Y . P R l M A R V CONTROL CABLE
11. P U L L E V . B A L A N C E C A B L E
12. TURNBUCKLE. R I G H T P R I M A R Y
1 3 . CABLE. R I G H T WING P R l M A R V
1 4 . CABLE. R I G H T FVSELAGE P R I M A R Y
1 5 . CABLE. LEFT F U S E L A G E P R I M A R Y
1 6 . TURNBUCKLE. LEFT PRIMARY
II . CABLE. L E F T WING P R I M A R Y
1 8 . CABLE. RbCHT B A L A N C E
1 9 . CABLE. LEFT B A L A N C E
2 0 . ROD. C A B L E G U A R D
2 1. BOLT. WASHER L N U T
2 2 . BOLT. WASHER L N U T
2 3 . BOLT. N U T , BUSHING L COTTER P I N
2 4 . TURNBUCKLE. BALANCE CABLE
2 5 . BOLT. B E L L C R A N K P I V O T
2 6 . BUSHING. B E L L C R A N K
2 7 . T E F L O N TUBE
2 ( PULLEV, PRIMARY CONTROL CABLE
--
-
Figure 27-3. Aileron Controls
Page 27-12
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
F. Remoie the cable puIle!.s attached t o t h e lower section of the control column tee bar ahsembl! b!
remo\ing the pulle! attachment bolt.
G . M o l e the cable guard located under the pulley cluster below the fuel selector by remo\ing the
cotter pin from the exposed end of the guard and sliding it t o the left o r right a s required.
H. Remo1.e the cotter pins used a s cable guards a t the pulley in the forward area of the floor opening
aft of the main spar.
I . Disconnect the cable from the control chain a t the control column tee bar assembly by remo! ing
the cotter pin. nut. bolt and bushing that connect the two together. Secure the chains in some manner t o
pre\.ent them from unwrapping from around the sprockets.
J . Drau. the cable back through the floor tunnel.
3. The primary control cable in either wing may be removed by the following procedure:
A . Remove the access plate t o the aileron bellcrank located on the underside of the wing forward o f
the inboard end of the aileron.
B. I f not pre\,iousl!, disconnected. separate the cable a t the turnbuckle located in the floor opening
aft of the main spar.
C. Disconnect the pulle!. guard pin from pulley.
D. Disconnect the cable from the forward end of the aileron bellcrank by remo\.ing the cotter pin.
nut. u,asher and bolt.
E . Draw the cable from the wing.
4 . Either balance cable may be removed by the following procedure:
.4. Separate the balance cable a t the turnbuckle in the right side of the floor opening aft of the main
spar.
B. I f the left balance cable is t o be r e m o ~ e dremove
.
thecotter pin used a s a cable guard at the pullel
in the center of the floor opening.
C. Remo\,e the access plate t o the aileron bellcrank located on the underside of thew ing fornard of
the inboard end of the aileron.
D. D~sconnectthe cable from the aft end of the aileron bellcrank by removing the cotter pin. nut.
uasher and bolt.
E. D r a u the cable from the wlng
I S S T A L L A T I O S OF AILERON C O N T R O L CABLES. (Refer to Figure 27-3.)
1 . The installation of either the right o r left primary control cable that is located in the fuselage ma! be
accomplished as follow s:
A . D r a u the cable through the fuselage floor tunnel.
B. Connecr the cable t o the end of the control chain and secure using bushing. bolt. nut and cotter
pin.
C. Place the cable around the pulle! that is located in the tunnel below the fuel selector.
D. Position cables and install the cable pulleys that attach t o the lower section of the tee bar
assembl!.. Secure with bolt. washer and nut.
E. Place the cable around the pulley that is located in the floor opening just aft of the main spar.
F . If the primary control cable in the wing is installed. connect the control cable end5 at thr'
turnbuckle located in the floor opening aft of the main spar.
G. Check rigging and adjustment per Rigging and Adjustment of Aileron Controls.
H. Position the heat duct and secure with screws.
1. Install the tunnel plate aft of tee bar assembly and secure with screws.
J . Put the floor carpet in place and secure.
K . Install the lou,er and upper selector covers and secure with screws.
L. Place the fuel selector knobs in place and secure with set screws.
27-1 1-02
Page 27-13
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2. The primary control cable in either wing may be installed by the following procedure:
A. Drat, the control cable into the wing.
B. Connect the cable t o the forward end of the aileron bellcrank usinga bolt. washer. nut and cotter
pin. Allot\ the cable end t o rotate freely o n the bellcrank.
C . I f the primarycontrol cable in the fuselage is installed.connect the ends at the turnbuckle located
under the center seat aft of the main spar.
D . Check rigging and adjustment per Rigging and Adjustment of Aileron Controls.
E . lnstall the access plate on the underside of the wing.
3. Either balance cable may be installed by the following procedure:
A. Draw the cable into the wing.
B. Connect the cable t o the aft end of the aileron bellcrank using a bolt. washer. nut and cotter pin.
Allow the cable end t o rotate freely on the bellcrank.
C . Connect the balance cable ends at the turnbuckle that is located under the center seat aft of the
main spar.
D . I f the left cable was removed. install the cotter pin cable guard at the pulley located uithin the
fuselage. aft of the main spar.
E. Check rigging and adjustment per Rigging and Adjustment of Aileron Controls.
F. Install the access plate on the underside of the wing.
4 . Replace the floor panel. center seat and the two iront seats.
A. Install the floor panel. seat belt attachments and seats.
I
A I L E R O S B E L L C R A S K ASSEMBLY.
RE'MOj'AL O F AILERO?; BELLCRANK ASSEMBLY. (Refer t o Figure 27-3.)
I . Remote the center seat and floor panel.
2. Remo\e the access plate t o the aileron bellcrank located on the underside of the w,ing. forttard of the
inboard end of the aileron.
3. Rclieie tension from the aileron control cables by loosening the balance cable turnbuckle located in
the opening aft of the main spar.
4 . D~sconnectthe primary and balance control cables from the bellcrank assembly b!, remo\ing cotter
pins. nuts. washers and bolts.
5 . Disconnect the aileron control rod a t the aft or forward end. a s desired. by remo\ ing the cotter pin.
nut. uasher and boll.
6 . Remote the nut. pit.ot bolt and washers that secure the bellcrank. The head of the pilot bolt is
accessible by remoting the access c a p on the t o p of the wing.
7 . Remo\e the bellcrank from within the wing.
I N S T A L L A T I O S OF AILERON BELLCRANK ASSEMBLY. (Refer t o Figure 27-3.)
1 . Ascertain that the bellcrank pi\.ot bushing is lubricated and install in the torque tube portion of the
bellcrank.
2. Place the bellcrank in position in the wing with a washer located between eachend of the torque tube
and the mounting brackets.
3. Install the bellcrank pit.ot bolt through the access hole of the upper wing surface. Install a washer and
nut on the bolt. and torque nut within 20 t o 25 inch-pounds. Check that the bellcrank rotates ireel!. with little
u p d o w n pla!.
4 . lnstall and adiust control rod and check aileron travel per Rigging
and Adjustment of Aileron
Controls.
Page 27-14
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-.)01/301T
MAINTENANCE MANUAL
5. Connect the ends of the primary and balancecontrol cables to the bellcrank using bolts. washers. nuts
and cotter pins. Allow the cable ends to rotate freely on the bellcrank.
6. Tighten the control cables at the balance cable turnbuckle in the floor opening aft of the main spar.
Check cable tension per Rigging and Adjustment of Aileron Controls.
7. Install the access plate on the underside of the wing, the floor panel, seat belt attachments and seats.
RIGGING AND ADJUSTMENT OF AILERON CONTROLS. (Refer t o Figures 27-5 and 27-6.)
Flap adjustment must be compkte w o r e starting aileron
a~uttment.
I
1. To check and adjust the rigging of the aileron controls. fvst set the right and left aileron bellcranks at
neutral position. (Ascenain that the control chains have k e n rigged per Installation of Control Column
Assembly.) This may be accomplished by the following procedure:
A. Remove the access plate to each aileron bellcrank located on the underside of the wing. forward
of the inboard end of the aileron by removing the plate attaching screws.
B. Affix a bellcrank rigging tool, as shown in Figure 27-5. between the forward arm of each
bellcrank and the adjacent rib. (This tool may be fabricated from dimensions given in Chapter 95.) The slotted
end of the tool fits on the arm forward of and adjacent t o the primary control cable end. The other end of the
tool is positioned so that the side of the tool contacts the aft side of the bellcrank stop. The bellcrank must be
moved to allow a snug fit of the tool between the bellcrank arm and rib. To d o so, it may be necessary to loosen
a primary control cable or the balance cable. Neutral position of the bellcranks is the position at which the
forward and aft cable connection holes are a n equal distance from the adjacent outboard wing rib.
2. With each bellcrank set at neut;al. the ailerons may be checked and adjusted for neutral as follows:
A. Ascenain that the bellcrank rigging tool fits snug between the bellcrank and the rib.
B. Place an aileron rigging tool as shown in Figure 27-6 against the underside of the wing and
aileron as close as possible to the inboard end of the aileron without contacting any rivets. The tool must be
positioned paralleled with the wing ribs, with the aft end of the tool, even with the trailing edge of the aileron.
(This tool mag be fabricated from dimensions given in Chapter 95.)
C. With the aileron control rod connected between the bellcrank and aileron. check that the surface
of the wing contacts the tool at its forward surface and a t the spacer. and the trailing edge of the flap contacts
the aft end of the tool. The aileron is neutral at this position.
D. Should the three points not contact, loosen the jam nut at the aft end of the control rod and
rotate the rod until the three points contact. Apply a slight up pressure against the trailing edge of the aileron
while making this adjustment. After adjustment, retighten the jam nut.
3. Adjust primary and balance cable tension as given in Figure 27-4 by the following procedure:
A. Remove the two front seats if desired, the center seat and floor panel to facilitate in the necessary
operation.
B. Loosen the connecting bolts of the idler cross-over sprockets at the control tee bar to allow the
chain to fit snug around the control wheel sprockets and over the idler sprockets.
C. Ascenain that both bellcranks are at neutral position.
27-1 3-00
Page 27- 15
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
NOTES
1 . Marlmum free play for aileron 1s
0 120 of an Inch. measured at
trall~ngedge
2 Maximum end play l~nboard/
outboard must not exceed ,035
of an Inch
AILERON UP TRAVEL
28" 2 1"
WING CHORD LINE
@ 53' upJ>
AILERON CHORD LINE
220-
CABLE TENSION
40 LBS 2 5 LBS
Figure 27-4. Aileron Rigging
Figure 27-5. Bellcrank Rigging Tool
27- 13-00
Page 27-16
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
SlflON OF AILERON WILL OCCUR WHEN
0 CHAPTER 95
~
I
Figure 27-6. Aileron Rigging Tool
D. Adiust the turnbuckles. located in the access opening just aft of the main spar. of the primar! and
balance cables to their proper cable tension and maintain neutral-center position of the control uheels. T o
ohtain neutral position of both control wheels. it ma!. also be necessary t o adjust the roller chain turnbuckle
located betueen the control uheel sprockets. During adjustment. obtain a little more tension on the primdr!
control cables t o hold the bellcranks in neutral against the rigging tools. finishing with e t e n tension on all
cables.
E. Tighten the bolts t o secure the idler cross-over sprockets.
F. Remove the aileron bellcrank rigging tool from each wing.
4 . Check the ailerons for correct travel from neutral per dimensions given in Figure 27-4 b! the
f o l l o inp
~ procedure:
A . Center rhe bubble of a protractor over the surface of a n aileron at neutral position and note the
reading.
B. \I on\e the aileron full up and down. and check the degree of travel for each direction. T h e degree
of Iran\ el o n the protractor is determined by taking the difference between the protractor reading at neutral and
up. and neutral and d o u n . The bubble must be centered at each reading.
C . Should the travel not be correct. the travel may be set by rotating the bellcrank stops in o r out.
Stops are l o c a ~ e din the wing attached t o the rib that is adjacent t o the aileron bellcrank.
D. Repeat this procedure for the other aileron.
27-1 3-00
Page 27-17
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
5 Check the bellcrank stops t o assure that the bellcrank contact is made simultaneously. but still h a \ c
cushion before contacting the control wheel stops. Maintain .030t o .040 clearance betbeen sprocket pin and
adjustable stop bolt+ on models having adjustable tee bar stops. .
6. Check complete system for operation and safety of turnbuckles. bolts. etc.. install all pulle!. guard
pins.
7 . Install access plates and panels.
When an out of trim condilion persists despite a11 the rigging
corrections that can be made, there is a possibility that there is a
slight bulging of the aileron contour at the trailing edge. This will
cause an out of rig condition that is very difficult to correct.
)
A I L E R O N I R U D D E R INTERCONNECT.
The aileron rudder interconnect consists of a spring-loaded cable located in the fuselage tunnel u hich
connects the aileron cable to the rudder cable. Application of full right rudder will result in a downuard
mo\,ement of the left aileron. thereby increasing aircraft stability in this particular rnaneu\er.
RIGGING A N D A D J L S T M E N T O F A I L E R O N I R U D D E R INTERCONNECT.
Aileron and rudder rigging must be completed prior to rigging
interconnect.
I. Remo\e the tunnel access co\,er. Position interconnect cables a s shown in Figure 27-7 and clamp.
Position the left clamp so that the spring will not touch the fuselage under an!. control position.
2. Li'ith the rudder pedals in neutral. rotate the control wheel from full right to full left.
7 . Engagement of the interconnect cable shall occur with thecontrol wheel passing between neutral and
a point IOC left of neutral.
A . Engagement can be detected by movement of the interconnect spring and a loud click as the
blocks on'the interconnect pulleys engage.
B. Should the interconnect cable not connect. reposition the right clamp f o r ~ a r do r aft as required.
27-14-01
Page 27-18
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANVAL
1.25 (APPROXIMATE)
- SEE NOTE -
.70(APPROXIMATE)
1 RUDDER CABLE
2 AILERON CABLE
3 CABLE CLAMP
4 W L L M CLUSTER
a
5 SPRING
6 INTERCONNECT CABLES
NOTE
THIS DIMENSION MAY VARY AS REQUIRED TO OBTAIN
RIGGING SPECIFIED IN "RIGGING AND ADJUSTMENT"
OF AILERON/RUDDER INTERCONNECT."
Figure 27-7. Aileron Rudder Interconnect
27-14-01
Page 27-19
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
I
R U D D E R A S D TAB,
1
R t ! D D E R COSTROL CABLES.
The rudder control cablesare of standard 1 8 inch. 7 x 19(seven strands of 19 wires per strand) gahanized
aircraft cord w hich has been dipped in a corrosion preventativecompound. Depending on the installation. the
cable may have swaged stud terminal ends. f o r k t n d strap fittings with swaged-ball terminal ends. or e!e-end
strap fittings with suaged-ball terminal ends.
REMOVAL O F RUDDER CONTROL CABLES. (Refer to Figure 27-8.)
1 . To remo\.e either the forward or aft rudder cable. first remove the access panel to the aft section of the
fuselage.
2. Disconnect the desired cable at the turnbuckle in the aft section of the fuselage.
3. Either forward rudder cable may be removed by the following procedure:
A . Rem0i.e the tunnel cover in the aft area of the cabin by removing the carpet over the tunnel and
the co\er attachment screus.
B. Rem0i.e the cable guard plate from the underside of the pulley cluster that is located in the aft
area of the floor tunnel. b!. remoi.ing the guard attachment screws.
C. Remo\,e the floor panel located directly aft of the main spar by removing the center seats. seat
belt attachments and the screws securing the floor panel. Lift the panel and remove from airplane.
D. From within the area of the floor opening. remove the cable rub blocks that are attached to the
spar housing b!. remoi.ing the block attachment screws. Also remove thecableguard pin at the pulle!.cluster in
the aft area of the opening by removing a cotter pin from one end of the guard.
E. Remote the fuel selector panel cover by removing the rudder trim knob and the co\er
attachment s c r e w .
F. Rem0i.e the lower selector cover. and the fuel selector control lever by removing the attachment
pin. at the bottom of the lei-er. that holds the lever on the selector torque tube.
G . Rem0i.e the tunnel plate just aft of the tee bar by removing enough carpet from the tunnel to
allow the plate attachment screws and the plate to be removed.
H. Rem0t.e the forward heat duct from one side of the floor tunnel. (Preferably from the side from
which the control cable is to be remo\.ed.)
I . M0i.e the cable guard located under the pulley cluster and below the fuel selector b!. remoiinp
the cotter pin from the exposed end and sliding it to the left or right as required.
J . Disconnect the end of the cable from the arm on the rudder pedal torque tube b!, remo\.ing the
cotter pin. nut. u.asher and bolt.
K . Drau the cable from the floor tunnel.
4. The aft rudder control cable may be removed by the following procedure:
A . Remo\e the tail cone by removing its attachment screws.
9. Disconnect the cable from the rudder horn assembly by removing the nuts. washers and bolts.
C. Dra\i the cable through the fuselage.
27-21-01
Page 27-20
Revised: August 1 1. 1983
a
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
~
~
I
I
1
i
~
I
i
I
~
~~
:
i
i
•
INSTALLATIOS O F RClDDER CONTROL CABLES:(Refer
to Figure 27-8.)
The foriiard rudder control cables may be installed by the following procedure:
A . Draw the control cable through the floor tunnel.
B. Connect the end of the cable to the arm on the rudder pedal torque tube by installing bolt.
w.asher. nut and cotter pin. Allow the cable end free to rotate.
C. Connect the cable to the aft control cable at the turnbuckles in the aft section of the fuselage. I f
the aft control cable is not installed. install at this time per Step 2. Ascertain that each cable is in thegroo\e of
its pulle!..
D. Mo1.e the cable guard that is located in the forward tunnel. under the pulley cluster and below
the fuel selector into position. and secure with cotter pin.
E. H'ithin the area of the floor opening aft of the main spar. install the cable guard blocks onto the
spar housing and secure with screws. and the cable guard pin at the pulley cluster in theaft area of the opening
b!, sliding it into position and fastening it with a cotter pin.
F. lnstall the cable guard plate under the pulley cluster located in theaft area of the aft floor tunnel
and secure with screws.
G . Set cable tension and check rigging and adjustment per Rigging and Adjustment of Rudder
controls.
H. Install the heat duct and secure with screws.
I . Install the forward tunnel plate aft of the tee bar and secure with screw-s.
J . Put the floor carpet in place and secure.
K Place the fuel selector le\.er on the selector torque tube and secure with pin and cotter pin.
L. Install the lower and upper selector covers and secure with screws.
M. Install the floor panel and seat belt attachment aft of the main spar securing the panel nith
screws. and install the seats.
.
lnstall the co\.er and carpet of the aft floor tunnel.
2 The aft control cable ma! be installed by the following procedure:
.4. Refer to Figure 27-8 to position the control cable.
B. Connect cable at turnbuckles in the aft sectin of the fuselage.
C. Install cable guard cotter pins abo\,e pulleys and at the aft portion of the sector assembl!.
D. Set cable tension and check rigging and adjustment per Rigging and Adjustment of Rudder
Controls
E . Install tail cone and secure with screws.
3. lnstall the access panel io the aft section of the fuselage.
1.
27-21-02
Page 27-21
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
RWDER & STEERING PEDAL ASSY.
BOLT. WASHER. NUT & COTIER PIN
BOLT. BUSHINGS. WASHER & NUT
GUARD PIN. CABLE
PULLEY CLUSTER
RUB BLOCKS
BOLT. BUSHINGS. WASHER & NUT
PULLEY CLUSTER
GUAFID PIN. CABLE
GUAFID PLATE, CABLE
BOLT. BUSHINGS. WASHER & NUT
PULLEY CLUSTER
CABLE. RIGHT FORWARD
CABLE. LEFT FORWARD
TURNBUCKLE. LEFT
TURNBUCKLE. RIGHT
CABLE. RIGHT AFT
CABLE. LEFT AFT
BOLT. BUSHING. WASHER & NUT
HORN. RWDER
Figure 27-8. Rudder Controls
Page 27-22
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-3011301 T
MAINTENANCE MANUAL
RIGGING A N D ADJUSTMEKT O F R U D D E R CONTROLS.
I.
To check and set the correct degree of rudder travel. the following procedure may be used:
A. Check the rudder travel by swinging the rudder until it contacts its stop. If the control cables are
connected. use the rudder pedals to swing the rudder.
B. N'ith the rudder against its stop. place a rigging tool against the side of the rudder and vertical
stabilizer as shown in Figure 27-9. (Ascertain that the tool is not contactingany rivets.) If no gap exists betw.een
the rigging tool and the surface of the rudder and vertical stabilizer. the rudder stop for one direction of tra\el
is correct. (This tool may be fabricated from dimensions given in Chapter 95.)
C. Swing the rudder in the other direction and check travel as directed in Step B.
D. Should the rudder travel be incorrect showing a gap between the tool and any part of the control
surfaces. the tail cone fairing should be removed and the stops reset to obtain correct rudder travel. (Refer to
Figure 27- 10.)
2. T o set cable tension and alignment of the rudder. the following procedure may be used:
A. Remove the access panel to the aft section of the fuselage.
B. Ascertain that the nose gear steering has been aligned and rudder pedals are clamped together in
neutral position. according to Alignment of Nose Landing Gear. Chapter 32.
C. Adjust the turnbuckles in the aft section of the fuselage to obtain proper cable tension and to
allow the rudder to align at neutral position.
D. Check safety of turnbuckles.
3. Adjust the rudder pedal stops by pushing on the pilot's left rudder pedal until the rudder stop is
contacted. Adjust the pedal stop (on the fire wall) to provide 0.06 t o 0.120 of an inch clearance. Repeat the
procedure u,ith the copilot's right rudder pedal. Do not push rudder harder than necessary to atoid cable
stretch.
4. Install the tail cone and the access panel to the aft section of the fuselage.
R I : D D E R T R I M COSTROLS.
REMOYAL OF RL'DDER T R l M COXTROLS. (Refer to Figure 27-13.)
1.
screw S.
2.
3.
uasher
Remo\,e the fuel selector panel cover by removing the rudder trim knob and the co\,er attachment
Place trim knob back on assembly and rotate to the extreme left (counterclockwise) trim position.
Disconnect the housing lug from the arm on the rudder pedal torque tube by removing cotter pin. nut.
and bolt.
4. Remo\.e the threaded bushing from the aft end of the mounting channel by removing cotter pin and
cle\.is pin.
5. The mounting channel may be removed by removing the channel attachment screws inside of the
channel. The middle and aft screws need only be turned out while the forward screw is secured b\,a nut on the
underside of the tunnel. T o remove the forward screw. lift the floor carpet on the right side of the tunnel
adjacent to the channel and remove the access plate on the side of the tunnel. Secure the nut and turn out the
screu .
27-23-01
Page 27-23
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
-
1. RUDDER TRAVEL ADJUSTMEN1
Figure 27-9. Rudder Rigging Tool
Figure 27-10. Rudder Travel Adjustments
la111
RUDDER TRAVEL
280 2 I * RIGHT a L E n
CABLE TENSION
65 LBS. 2 5 LBS
Figure 27-1 1. Rudder Rigging
Figure 27-1 2. Clamping Rudder Pedals
27-23-01
Page 27-24
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
INSTALLATION OF RUDDER TRIM CONTROLS. (Refer to Figure 21-13.)
I . Install the trim control mounting channel on the upper side of the floor tunnel. A spacer plate is
installed between the channel and the tunnel. Install the middle and aft attachment screws. These screws are
secured with anchor nuts. The forward screw is secured with a nut that must be held from within the tunnel.
2. Install the access plate on the side of the tunnel and secure carpet in place.
3. Before attaching the assembly to the mounting channel, ascertain that the clips are installed so the
safety wire will be on top. Also that the threaded bushing is installed on the assembly shaft with the welded
attachment bushing forward or toward the housing.
4. Attach the housing lug to the arm provided on the rudder pedal torque tube and secure with bolt.
washer and nut. Tighten the nut only finger tight and safety with cotter pin.
5. Clamp the rudder pedals in neutral (refer t o Chapter 32 for rudder pedal neutral position). and
position the threaded bushing and shaft extension in the mounting channel and then install the clevis pin and
cotter pin. Ascertain that dimensions noted in Figure 27-13 are maintained.
6. Reinstall items removed t o gain access to rudder trim control.
7. Ascertain that neutral indicator aligns with neutral position on the cover placard.
RIGGING A N D ADJUSTMENT OF RUDDER TRIM CONTROLS.
No adjustments are necessary other than those required duringinstallation of the assembly in the airplane
as given in Installation of Rudder Trim Controls.
27-23-03
Page 27-25
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
R U D D E R A N D STEERING PEDAL ASSEMBLY.
REMOVAL O F RC'DDER A N D STEERING PEDAL ASSEMBLY. (Refer to Figure 27-14.)
1. Remove the access panel t o the aft section of the fuselage.
2. Relieve rudder and stabilator cable tension by loosening one of the rudder and stabilator cable
turnbuckles in the aft section of the fuselage.
3. Remove the fuel selector panel cover by removing the rudder trim knob and the coker attachment
screws.
4. Remove the lower selector cover and disconnect the fuel selector control lever from the selector
torque tube by removing the attachment pin located at the bottom of the lever.
5. Remove the tunnel plate just aft of the tee bar by laying back enough tunnel carpet to remove the plate
attachment screws.
6. Disconnect the stabilator control cable from the lower end of the tee bar assembly.
7. Remove the tee bar attachment bolts with their washers and nuts which are through each side of the
floor tunnel. Pull the lower end of the tee bar aft.
8. . Disconnect the control cable ends from the arms of the torque tube by removing the cotter pins.
washers. nuts and bolts.
9. Disconnect the rudder trim from the torque tube assembly by removing the cotter pin. nabhers a n d
bolt that connects the arm to the trlm.
10. Disconnect the steering rods at the rudder pedals by removing nuts and bolts.
11. Disconnect the brake cylinders at the lower end of each cylinder rod by removing the cotter pins.
washers. nuts and bolts.
12. Disconnect the vee brace(s) from the torque tube by removing nuts, washers and bolts that secure the
strap bracket to the vee brace.
3
If an Autopilot amplifier is installed over the torque tube at the right side of the fuselage. d~sconnect
the electrical plug and release the two fasteners that secure it to its mounting bracket.
14. Disconnect the torque tube support bracket where it attaches t o the floor tunnel by remo\ing its
attachment bolts.
I . Remove the two bolts that extend through the torque tube and are located at the center of the tube
assembly over the floor tunnel. Compress the tubes.
16. Disconnect the torque tube support blocks from their support brackets on each side of the fuselage b!
removing the attachment nuts. washers and bolts.
17. Remo\se the trim side panels. if desired.
18. R e m o e~ the assembl? from the airplane. Note the spacer washer on each end and between the support
blocks.
P,age 27-26
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 / 3017'
MAINTENANCE MANUAL
IS. DOLT. W A S H L R L NUT
26. W L T . WASHER b N U T
I . TUBE. L OUTER
? T U B E . L . CENTER
I . T U B E . II CENTER
4
5
6
1
I
TUBE. R OUTER
PLITE
BOLT L N U T
SUPPORT BLOCK. UPPER
SUPPORT BLOCK. LO WE^
9.
10
11.
I?
13.
14
IS,
I6
WASHER. SPACER
ARM. IDLER
ROD. DRAKE CVLINOE n
BRAKE CVLlNDE R
CLEVIS PIN b COTTER P I N
TUDE. RUDDER C O N T R O L
CLEVIS ROD
C L E V I S P I N L COTTER P I N
17. CLEVIS E N 0
18. T O E B R A K E C E D A L
19. C O N T R O L C A B L E . R U D D E R
20. W L T . WASHER. N U T L COTTER P I N
21. DUNGEE. NOSE W H E E L STEERING
21. JAW NUT
23. ROD E N D . 8 U N C E E
24
W L T L NUT
221.
7.
29.
30.
11.
)I.
13.
11.
3s.
DOLT.
b NUT
B R A C KWASHER
ET
VEE DRACE
C L E V I S P I N A COTTER P I N
R U D D E R PEDAL. L . O m E R
R U D D E R PEDAL. L I N N E R
R U D D E R PEDAL. II.I N N E I
R U D D E R P E D A L . R OUTER
B R A C K E T , TUBE SUPPORT
Figure 27- 14. Rudder and Steering Pedal Assembly
27-24-01
Page 27-27
Revised: August 11. 1983
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLY. (Refer tb Figure 27-14.)
1. Assemble the torque tube assembly as shown in Figure 27-14. Do not at this time install the two bolts
through the center of the tube assembly.
2. Place the upper support blocks on the ends of the torque tube assembly. Note that a washer is
required on each end of the tube.
3. Position the support blocks on their mounting brackets at each side of the fuselage and secure with
bolts. washers and nuts. Note that a bushing is required in the bolt holes ofthe upper suppon block. and a plate
on top of the upper block, between the upper and lower blocks and under the block mounting bracket.
4. Align the bolt holes in the center area of the torque tubeassembly, install bolts, washers and nuts and
tighten.
5. Position the torque tube support bracket on the floor tunnel and secure with bolts.
6. Position the vee brace(s) on the torque tube, install the strap bracket around the torque tube and
brace, and secure with bolts, washers and nuts.
7. Connect the ends of the brake cylinder rods and clevis rods to the idler arms and secure with clevis and
cotter pins.
8. Connect the steering rods to the rudder pedals and secure with bolts and nuts. Check steering rod
adjustment per Alignment of Nose Gear, Chapter 32.
9. Connect the rudder trim to the arm of the torque tube and secure with bolt, washer, nut and cotter
pin. A thin washer is installed under the nut which is tightened only finger tight.
10. Connect the ends of the rudder control cables to the arms provided on the torque tube and secure with
bolts. washers, nuts and cotter pins. Allow the ends free to rotate.
I I. Swing the tee bar into place and secure with attachment bolts, washers and nuts with the bolts
inserted through each side of the floor tunnel.
12. Connect the stabilator control cables to the lower end of the tee bar with bolt. washer and nut. and
secure with cotter pin. Allow the cable ends free to rotate.
13. Set rudder cable tension and check rigging and adjustment. Rigging and Adjustment of Rudder
Controls.
14. Set stabilator cable tension and check rigging and adjustment. Rigging and Adjustment of Stabilator
Controls.
IS. Check aileron cable tension.
16. Check safety of bolt and turnbuckles.
17. Install the floor tunnel plate and secure with screws. Fasten the tunnel carpet in place.
18. lnstall the fuel selector lever on the selector torque tube, secure with clevis pin and safety with cotter
pin.
19. lnstall the fuel selector covers and the rudder trim control knob.
20. lnstall the access panel to the aft section of the fuselage.
Page 27-28
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301130 1T
MAINTENANCE MANUAL
1 TEE BAR CONTROL COLUMN
2 CABLE. RIGHT FORWARD
3 CABLE LEFI FORWARD
4 CABLE. LEFT - LOWER AFT
5 CABLE RIGHT UPPER AFT
6 PULLEY. FORWARD CLUSTER
7 PULLEY. A F I
8 BOLT. WASHER NUT & C O m R PIN
9 BOLT. WASHER & NUT
10 BLOCK. CABLE RUB
11 GUARD CABLE
12 BOLT WASHER (71 & NUT
1 3 BOLT. WASHER I1 1 ) & NUT
14 PULLEY. FORWARD
15 BOLT. WASHER. NUT & GOITER PIN
1 6 TURNBUCKLE
17 WEIGHT BALANCE ARM
18 BALANCE ARM. STABILATOR
-
Figure 27-1 5. Stabilator Controls
27-24-02
Page 27-29
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
1
STABILATOR A N D TAB.
( STABILATOR CONTROL CABLES.
The stabilator control cables are of 118 inch. 7 x 19 (seven strands of 19 wires per strand) gal\.anized
aircraft card which has been dipped in a corrosion preventative compound. Depending upon the installation.
the cable may have swaged stud terminal ends. f o r k t n d strap fittings with swaged-ball terminal ends. or eyeend strap fittings with swaged-ball terminal ends.
REMOVAL O F STABILATOR CONTROL CABLES. (Refer to Figure 27-15.)
I . T o rem0j.e either the forward or aft stabilator cables. first remove the access panel t o the aft section of
the fuselage.
2. Disconnect the desired control cable at the turnbuckle in the aft section of the fuselage.
3. Either forward stabilator cable may be removed by the following procedure:
A . Remove the floor tunnel cover in the aft area of the cabin by removing the trim plate. the carpet
o\.er t'he tunnel and the co\,er attachment screws.
B. Remove the cable guard plate from the underside of the pulley cluster in the aft area of the tunnel
opening by removing the guard attachment screws.
C. Remove the floor panel located directly aft of the main spar by removing the center seats. seat
belt attachments and the screws securing the panel. Lift the panel and remove from airplane.
D. Within the floor opening. remove the cable rub blocks that are attached to the spar housing b!,
remo\.ing the block attachment screws. Also remove the cotter pin cable guard at the pulle? cluster in the aft
area of the opening.
E. Remove the fuel selector panel cover by removing the rudder trim knob and the co\.er
attachment screws.
F. Remove the lower selector cover and disconnect the fuel selector control lever from the selector
torque tube by removing the attachment pin located at the bottom of the lever.
G . Remove the tunnel plate just aft of the tee bar by removing enough carpet from the tunnel to
allow the plate attachment screws and plate to be removed.
H. If the right (upper) stabilator control cable is to be removed. remove the cotter pin cable guards
at the pulley located in the forward area of the tunnel.
I . Disconnect the cables from the lower end of the tee bar by removing the cotter pin. nut. washer
and bolt.
J . Draw the cable aft through the floor tunnel.
4. Either aft stabilator control cable may be removed by the following procedure:
A . Disconnect the cable end at the balance weight tube by removing thecotter pin. nut. u,asher and
bolt.
.
B. Remot-e the cable guard pin at the pulley.
C . Remoi-e the cable from the airplane.
Page 27-30
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
•
INSTALLATION O F STABILATOR CONTROL CABLES. (Refer t o Figure 27- IS.)
I. The forvsard stabilator cables may be installed by the following procedure:
A. Draw the control cable through the floor tunnel. Ascertain that the right (upper) cable is routed
around the pulley that is in the forward area of the forward floor tunnel.
B. Connect the cables to the lower end of the control column tee bar with bolt. washer, nut and
cotter pin. Allow the cable to be free to rotate.
C. If the aft control cable is not installed, install per Step 2.
D. Connect the control cable to the aft cable at the turnbuckle in the aft section of the fuselage.
E. For the right control cable. install the cotter pin cable guard at the pulley in the forward area of
the tunnel.
F. Within the forward area of the floor opening aft of the main spar, install the cable rub blocks to
the spar housing and secure with screws.
G. In the aft area of the floor opening. install the cotter pin cable guard at the pulley cluster
H. Install the cable guard under the pulley cluster located in the aft area of the aft floor tunnel and
secure with screws.
I. Set cable tension and check rigging and adjustment per Rigging and Adjustment of Stabilator
Controls.
J . Install the tunnel plate directly aft of the tee bar assembly and secure with screws.
K. Put the floor carpet in place and secure.
L. Place the fuel selector lever on the selector torque tube and secure with pin and safety w ~ t hcotter
pin.
THIS SPACE INTENTIONALLY LEFT BLANK
27-31-02
Page 27-31
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
M. Install the lower and upper selector coven and secure with screws.
N. Install the floor panel aft of the main spar and secure with screws. Install the seat belt
attachments and seats.
0. Install the cover and carpet of the aft floor tunnel.
2. Either aft stabilator control cable may be installed by the following procedure:
A. Route the cable under pulley.
B. Connect the cable to the stabilator balance weight tube and secure with bolt. washer, nut and
cotter pin. (Tighten nut "finger tight' only.)
C. Connect the cable to the forward cable at the turnbuckle in the aft section of the fuselage. The
upper aft cable connects to the right forward cable and the lower cable to the left cable.
D. Install the cable guard pin at the pulley.
E. Set cable tension and check rigging and adjustment per Rigging and Adjustment of Stabilator
Controls.
3. Install the access panels to the aft section of the fuselage.
RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS.
I. To check and set the correct degree of stabilator travel, the following procedure may be used:
A. Level the airplane. (Refer to Leveling, Chapter 8.)
B. Place the stabilator in neutral position. Neutral position is obtained when a level placed on
stabilator rigging tool (Figure 27-16) indicates that stabilator is parallel. with the top of the front seat track
noted in Figure 27-16.
C. Check the stabilator travel by placing a rigging tool on the upper surface of the stabilator as
shown in Figure 27-16. (This tool may be fabricated from dimensions given in Chapter 95.)
D. Set on a bubble protractor the number of degree up travel as given in Figure 27- 16 and place it on
the rigging tool. Raise the trailing edge of the stabilator and determine that when the stabilator contacts its
stops. the bubble of the protractor is centered.
The stabilator should contact both of its stops bejore the control
wheel contacts its stops.
E. Set on the protractor the number of degrees down travel as given in Figure 27- 16 and again place
it on the rigging tool. Lower the trailingedge of thestabilatorand determine that when it contacts its stops. the
bubble of the protractor is centered.
F. Should the stabilator travel be incorrect in either the up or down position, remove the tailcone
fairing by removing the attachment screws and with the use of the rigging tool and bubble protractor turn t h e
stops located at each stabilator hinge in or out to obtain the correct degree of travel. (Refer to Figure 27- 17.)
G. Ascertain that the locknuts of the stop screws ate secure and then reinstall the tailcone fairing.
2. To check and set stabilator control cable tension, the following procedure may be used:
A. Ascenain that the stabilator travel is correct.
B. Remove the access panel to the aft section of the fuselage and tailcone fairing.
27-32-00
Pnee 27-32
Revised: August 1. 1983
PIPER AIRCRAFT
P.4-32-301/301T
31AISTES.ANCE M A S U A L
I
I
STA BI LATOR CHORD LlN E
(NEUTRAL POSITION)
(SEE NOTE)
/-
-4
Neutral posltion of stabilator Is with thd rtrbllator
chord Ilrm prrailet wlth the top of the front wrt
trackr
Stabilator
A.
STABILATOR TRAILING EDGE UP TRAVEL A.
FROM NEUTRAL
14.5'f
B-
Stabilator Trim Tab
.so
STAB1 LATOR TRAILING EDGE DOWN
TRAVEL FROM NEUTRAL
5.5: 2 0.5'
CABLE TENSION 40 LBS. 2 5 LBS.
B.
STABILATOR TAB TRAILING EDGE
UP TRAVEL FROM NEUTRAL
Sotlo
STAB1LATOR TAB TRAILING EDGE
DOWN TRAVEL FROM NEUTRAL
8" 21"
1 LBS
CABLE TENSION 14 LBS
STABI LATOR CHORD LINE
(NEUTRAL POSITION)
(SEE NOTE 2)
'
1.
2.
Maximum free play for control surfam tab Is
0.06 of an inch m m r d at tab trrlling Odw.
Neutral posltion of rtrbllrt# b with the
drbilator chord line paralW with th. to0 of
the tront owt tracks.
I
B
Figure 27-16. Stabilator Rigging.
27-32-00
Page 27-33
Revised: August l I . 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
C. Secure the control column in the near fomard position. Allow onequarter inch between the
column and the stop bumper.
D. Check each control cable for the correct tension as given inFigure 27-16.
E. Should tension be incorrect, loosen the turnbuckle of the lower cable in the aft section of the
fuselage and adjust the turnbuckle of the upper cable to obtain correct tension. Cable tension should be
obtained with control wheel at the onequarter inch dimension from the stop and the stabilatorcontacting its
stop.
F. Check safety of all turnbuckles and bolts.
G. With the tension of the upper cable comct and the control wheel still forward, adjust the
turnbuckle of the lower cable to obtain correct tension.
H. Check the full travel of the control wheel with relation to the full travel of the stabilator to
deterine that the stabilator contacts its stop before the control wheel contacts its stops. With the control wheel
in the fore and aft positions, the trawl distance from the point where the stabilator contacts its stops and the
control wheel contacts its stops should be approximately equal. Readjust turnbuckles if incorrect.
I. Reinstall access panels and fin tip.
THIS SPACE INTENTIONALLY LEFT BLANK
27-32-00
Page 27-34
Revised: August 11, 1983
Y l Y E W AIKLKAP 1
PA-32-301/ 30 1T
MAINTENANCE MANUAL
Figure 27-17. Stabilator Travel Adjustments
Figure 27-18. Methods of Securing Trim Cables
27-32-00
Pane 27-35
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
STABILATOR TRIM.
REMOVAL O F STABILATOR TRIM ASSEMBLY (FORWARD). (Refer to Figure 27-19.)
1. To remove the trim control wheel assembly and/or the trim control cables, first remove the panel to
the aft section of the airplane.
2. If the aft trim cable is not to be removed, block the cables a t the pulleys in the aft section of the
fuselage to prevent them from unwrapping from the trim drum. (Refer to Figure 27-18.)
3. Loosen the cables if the trim control wheel is to be removed or disconnect if the cables are to be
removed. Do this at the trim cable turnbuckles in the aft section of the fwciage.
4. The control wheel with drum may be removed by the following procedure:
A. Remove the control wheel cover by removing the cover attaching screws.
B. The wheel assembly may be removed from its mounting brackets by removing nut, washer and
bolt that secures the wheel between the brackets. Draw the wheel from the brackets. Use caution not to
damage trim indicator wire.
C. Unwrap the left cable from the dwm.
D. The wheel and drum are joined by a push fit, separate these two items with their center bushing
and unwrap the right cable.
E. Tie the cables forward to prevent them from slipping back into the floor tunnel.
5. The trim control cables may be removed by the following procedure:
A. Remove the pilot and rear seats if desired.
B. Remove the seat belts attached to the forward floor tunnel by removing attachment nuts.
washers and bolts.
C. Remove the heater deflectors from each side of the aft end of the forward floor tunnel by sliding
the deflector sideways and releasing the retainer spring.
D. Unfasten the carpet from the aft ponion of the forward floor tunnel and lay it forward.
E. Remove the tunnel cover located between the trim control wheel and the spar cover by removing
the selector knobs and cover attachment screws.
F. Remove the cable pulleys located in the forward tunnel by removing the cotter pin, washer and
clevis pin.
G. Remove the floor panel aft of the main spar by removing the panel attachment screws and seat
belt attachments. Lift the panel and remove from airplane.
H. Remove the cable rub blocks located in the floor opening on the aft side of the main spar by
removing the block attachment screws.
I. Remove the trim plate located on top of the forward end of the aft floor tunnel.
J. Remove the carpet from the aft floor tunnel.
K. Remove the cover plate from the top of the aft floor tunnel by removing attachment screws.
1. Remove the cable guard from the underside of the trim cable pulleys located in the forward area
of the aft floor tunnel by removing a tinnerman nut and withdrawing the cable guard.
M. Remove the cable guard plate from the underside of the pulley cluster located in the aft area of
the floor tunnel by removing the plate attachment screws.
N. Remove the cable guard from the cable pulleys in the aft lower section of the fuselage forward of
the cable turnbuckles.
0. With the cables disconnected from the trim control wheel, draw the cable(s) through the floor
tunnel.
27-33-01
Page 27-36
Revised: August 11, 1983
PIPER A I R C R A F T
PA-32-301/301 T
MAINTENANCE MANUAL
CONTROL WCI EEL TRlM
INDICATOR, TRlM POSITION
DRUM. TRlM CABLE
MOUNTING BRACKET
CLEVIS PIN. WASHER & COnER PIN
PULLEY CLUSTER
BOLT. BUSHING. WASHER & NUT
CABLE. RIGHT FORWARD
CABLE. LEIT FORWARD
TURNBUCKLE. RIGHT
TURNBUCKLE. LEFT
CABLE. A F I
PULLEY CLUSTER
BOLT. BUSHING. WASHER (3) & NUT
n
15
16
17
18
19
20
21
22
23
24
25
-
GUARD BOLT. BUSHING. WASHER & NUT
RIB. HORIZDNTAL SUPPORT
PLATE. RIB
GUARD
BUSHING. BARREL
BARREL TRIM
CUP. DLAGOWL RIB
RIB. DIAGONAL SUPPORT
SCREW. TRIM
BOLT. WASHER (2) & NUT
LINK
26
27
28
29
30
31
32
33
34
35
36
37
38
39
BOLT WASHER (2) & NUT
J A M NUT
ARM. TRIM CONTROL
BUSHING BARREL
WASHER THRUST
WASHER SPACER
SNAP RING
GUARD CABLE
PULLEY CLUSTER
PULLEY CLUSTER
PULLEY CLUSTEP
BOLT. WASHER 81 NUT
GUARD CABLE
RUB BLOCK
Figure 27-19. Stabilator Trim Controls
27-33-01
Page 27-37
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD). (Refer to Figure 27-19.)
1. The trim control wheel with drum may be installed by the following procedure:
A. Wrap the right trim cable on the trim drum by inserting the swagged ball of the cable in the slot
provided in the sidc (right side) of the drum that mates with the control wheel, and looking a t this side, wrap
the drum with three wraps of the cable in a clockwise direction.
B. Attach the control wheel to the cable drum by aligning the long lug of the drum with the long
slot of the wheel and pushing the two pieces together.
C. Wrap the left trim cable on the drum by inserting the swagged ball of the cable in the slot
provided in the flanged side (left side) of the drum and looking at this sidc, wrap the drum with three wraps of
the cable in a clockwise direction.
D. Lubricate and install the bushing in the control wheel and drum.
E. Align the control cables and position the control wheel assembly between its mounting
brackets. Ascertain that the end of the trim indicator wire is positioned in the spiraled slot of the drum with no
bind on the end. lnstall the retainer bolt from the left side and install washer and nut.
F. Install the cover over the control wheel and secure with screws, unless the control cables have yet
to be installed.
2. The trim control cables may be installed by the following procedure:
A. Draw the cable(s) through the floor tunnel.
B. Wrap the cable drum and install the trim control wheel as given in Step 1.
C. Position the cable pulleys on their mounting bracket and install the clevis pin, washer and cotter
pin.
D. Connect the cablc to the aft cable at the turnbuckle in the aft section of the fuselage. lnstall aft
cable if not installed.
E. lnstall the cable guard at the cable pulleys in the aft lower section of the fuselage forward of the
cable turnbuckles.
F. lnstall the cable guard plate at the underside of the pulley cluster located in the aft area of the aft
floor tunnel and secure with screws.
G. Install the pin type cable guard a t the underside of the pulleys located in the forward area of the
aft floor tunnel and secure it with a tinnerman nut.
H. Install the cable rub blocks located on the aft side of the main spar housing and secure with
screws.
I. Remove the blocks that secure the aft trim cable and check that the cables are seated on their
pulleys.
J. Set cable tension and check rigging and adjustment. Check safety of all turnbuckles.
K. Install the tunnel cover on the forward tunnel and secure with screws.
L. lnstall the carpet over the floor tunnel.
M. lnstall the heat deflectors on each side of the floor tunnel.
N. lnstall the cover over the trim control wheel and secure with screws and special washers.
0. lnstall the fuel selector knobs and secure with set screws.
P. Install the seat belts removed from the top of the floor tunnel and secure with bolt, washer and
nut.
Q. lnstall the floor panel and seat belt attachments aft of the main spar, and secure panel with
screws.
R. Install the aft floor tunnel and secure with screws.
S. lnstall the carpet over the aft floor tunnel.
T. Install the trim plate on top of the forward end of the aft floor tunnel.
3. lnstall the panel to the aft section of the airplane and the seats.
27-33-02
Page 17-38
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
a
1
1. Remove the access panel to the aft section of the fuselage.
2. Block the trim cables at the first set of pulleqs forward of the cable turnbuckles in the aft section of the
fuselage by method shown in Figure 27-18.
3. Disconnect the cable at the turnbuckles in the aft section of the fuselage.
4. Remove cable guard from pulley cluster and cable guards from pulley cluster.
5. Remove the tailcone by removing attachment screws.
6. Disconnect the link between the trim screw and the trim control arm by removing the nut. washer and
bolt that connects the link to the screw.
7. Remove the cotter pin from the top of the screw and turn the screw down and out of the barrel.
8. Remove the snap ring, washer and thrust washer from the bottom of the barrel.
9. Disconnect the diagonal rib from the horizontal rib that supports the trim assembly by removing the
four attachment nuts. washers and bolts.
10. Draw the trim cable from the fuselage.
INSTALLATIOIS OF STABILATOR TRIM CONTROLS (AFT). (Refer to Figure 27-19.)
a
I
REMOVAL OF STABILATOR TRIM CONTROLS (AFT). (Refer to Figure 27-19.)
1 . Wrap the trim barrel by first laying the center (as measured equally from each end to the center of the
cable) of the trim cable in the slot of the barrel. Bring the half of the cable t o be used on the right side through
the diagonal slot in the flange at the forward end of the barrel and wrap aft in a clockwise direction 7 wraps to
the center of the barrel. Bring the half of the cable t o be used on the left side through the diagonal slot in the aft
end of the barrel and wrap forward in a counterclockwise direction 7 wraps to the center of barrel. Count a
total of 14 cable wraps on the top side of the barrel. (Refer to Figure 27-20.)
2. Block the cable by clamping the cable between two pieces of wood laid next to the wraps to prevent
unwrapping. Fabricate block with a notch so hardware can be installed. After installation of hardware safety
wire the bolts.
3 . Ascenain that the barrel bushings are installed in the rib plate and clip.
4. Lubricate the bushings and install the tnm barrel in the bushings between the two support ribs.
Attach the bottom diagonal rib to the horizontal rib and secure with bolt. washer and nut.
5. lnstall the thrust washer, washer and snap ring on the lower end of the barrel.
6. lnstall the trim-screw in the barrel and secure each end with a cotter pin through the scren..
7. Route the cables into the fuselage and attach the ends to the forward trim cables.
8 . Remove the blocks that are holding the forward cables tight.
9. Set cable tension and check rigging and adjustment per Rigging and Adjustment of Stabilator Trim.
Check safety of all turnbuckles.
10. lnstall the tailcone and secure with screws.
I I . lnstall the access panel to the aft section of the fuselage.
HlCClNG AND ADJUSTMENT OF STABILATOR TRIM. (Refer to Figure 27-19.)
1 . Le\el the airplane. (Refer to Leveling. Chapter 8.)
2. Check for proper stabilator trim cable tension as given in Figure 27-16. If cables were disconnected.
rotatc control wheel several times to allow the cables to seat and recheck tension.
3. Secure the stabilator in neutral position. T o find neutral, place a rigging tool on the upper surface of
the stabilator as shown in Figure 27-16. Zero a bubble protractor. set it on the rigging tool and tilt the
stabilator until the bubble is centered.
4 . With the stabilator centered. turn the trim wheel until the aft end of the turnbuckle of the right trim
cable 1s approximately two inches forward of the double pulleys at the top of the rear bulkhead.
27-33-02
Page 27-19
Revised: August 11. 1983.
PIPER AIRCRAFT
PA-31-301/301T
3IAISTESASCE M A S L A L
n
BARREL
WRAPS
Figure 27-20. Wrapping Trim Barrels
RIGGING TOOL (REFER
TO CHAPTER 95)
Figure $7-2 1 . Stabilator Rigging Tool
27-33-05
Page 27-JO
Revised: August 11. 198.3
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANL'AL
5 . Check that the trim screw- is turned down until the cotter pin stop in the top of the screu is contacting
the plate on the hnri7ontal support rib of the trim assembly. If the stop is not contacting the plate. and the links
betw.een the scrcu and the trim control arm are not disconnected. disconnect the two b!, remo\ ing t hc nut.
washers and bolt. U'ith the turnbuckle still at the two inch dimension from the pulley. turn the screw down
until the pin contacts the plate.
6. Check the rod end on the t a b actuating arm for approximately six threads forward of the jam nut.
7. Connect the links t o the trim screu and secure the bolt. washers and nut.
8. Turn the trim control wheel until the trim t a b streamlines with the neutral stabilator.
9. Check the bubble of the protractor over the neutral t a b and then check t a b travels as gi\en in Figure
27-16, The degree of tra\el on the protractor is determined by taking the difference between the protractor
reading at neutral and up. and neutral and down. The bubble must be centered at each reading uith thc
airplane level.
10. T o obtain correct tra\-els. if incorrect. adjust by disconnecting the links at the actuating arm rod end
and turning the end in o r out a s required. Reconnect links t o rod end.
I I . Secure the jam nut on the actuating a r m rod end.
12. Turn the trim wheel to full travel and check for turnbuckle clearance and location of tab indicator.
1
FLAPS.
1
W'INC F L A P CONTROLS.
1
REMOF'AL O F MAHL'ALLY O P E R A T E D WING FLAPS. (Refer t o Figure 27-22.,
I.
The flap torque tube assembl! ma!. be remo\ed by the following procedure:
. A . Rcmoie the access plate located between the underside of the aft section of each uing and the
fu*elage b! remo\-ing attaching screus.
B. Rern0t.e the floor panel located aft of the main spar by remo\.ing the center seats. >eat bclt
attachments and the screus securing the panel. Lift the panel and remo\.e from airplane.
C . Dibconnect the left and right flap control tubes (rods) a t the flaps b!.remo\.ingthe nuts. u a s h c r ~
and bolts or at the torque tube cranks (arms) b! remo\,ing the bolts and washers from the inner side ot'edch
crank. I t u i l l be necessar!. to remove bolt through a hole in the side skin of the fuselage located o \ e r the torque
tube u.ith :he flap handle mo\.ed t o its 40 degree position.
D. U'ith the flap handle. fully extend the flaps and disconnect the flap tension spring at the cpar or
the aft end of the control cable a s desired.
E. Grasp the flap handle. release the plunger and allow the flap t o return to the retracted position.
1:se caution as forward pressure will be on the handle with the tension spring disconnected.
F. Disconnect the flap return spring at the spar or return chain as desired.
G. Disconnect the control cable from the chain by removing cotter pin. nut. and cle\ i > bolt.
H. Remo\e the tube support blocks by remo\ing the block attachment bolts.
I . Rernme the nuts. washers and bolts securing the right and left cranks and stop fittings on the
torque tube.
J . From between each wing and the fuselage. remove the cranks from the torque tube.
K . Disconnect one bearing block from its mounting brackets by removing nuts. washers and bolts.
L. Slide the tube from the bearing block still attached t o its brackets. raise the end and lift it from
the floor opening.
27-51-01
Page 27-41
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2. The flap control cable may be removed by the following procedure:
A. If the center seats and floor panel have not been removed, remove the seats and the SCRWS
securing the floor panel.
B. Disconnect the flap tension spring from the cable if not previously disconnected, by extending
the flaps to relieve spring tension.
C. Retract the flap. Use caution as forward pressure will be on the handle with the spring
disconnected.
D. Disconnect the cable from the chain by removing cotter pin, nut, clevis pin and bushing.
E. Remove the flap handle bracket and trim control wheel cover.
F. Remove the aft heat deflectors on each forward floor tunnel by sliding far enough to release the
spring fasteners.
G. Lift the aft section of the tunnel carpet far enough to remove the screws securing the tunnel
cover that is between the flap handle and the spar cover. Remove the cover.
H. Remove the cotter pin cable guard from the flap cable pulley located inside the floor tunnel just
ahead of the spar housing.
I. Remove the cable rub blocks located in the floor opening on the aft side of the spar housing by
removing the attachment screws.
J. Disconnect the cable turnbuckle at the flap handle by removing cotter pin, nut and bolt.
3. Remove the flap handle and bracket by disconnecting the cable turnbuckle from the handle and
removing the bolts securing the bracket to the floor tunnel.
I. B I A C l E T . I 0 0 ATTACMMEUT
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BUTTON. VLAP IELEASE
36.
nUS I L O C I
BAVETT C O T T C I P I *
ST.
m~n~na
ncrunu
,
Figure 27-22. Manually Operated R a p System
27-51-01
Page 27-42
Revised: ~ u ~ u s t 1984
9,
PlPad AlHCHAr 1'
PA-32-301/301T
MAINTENANCE MANUAL
INSTALLATION OF MANUALLY OPERATED WlNC FLAPS. (Refer to Figure 27-22.)
1. The flap torque tube assembly may be installed by the following procedure:
A. lnstall the chain sprockets with chains on the torque tube and secure with bolts, washers and
nuts.
B. Slide the tube stop fittings on their respective ends of the torque tube.
C. Ascenain that one bearing block fitting is installed between its attachment brackets.
D. Slide the other bearing block over its respective end of the torque tube.
E. Position the torque tube by placing the end with the bearing block on it between the mounting
bracket and sliding the other end into the previously attached bearing block.
F. Position the remaining bearing block and secure with bolts, washers and nuts.
G. Push the torque tube cranks (arms) on each end of the torque tube and slide the stop fitting in
place. Align the bolt hole of the crank and stop fitting with the holes in the torque tube, and install bolts. The
holes in the stop fitting are elongated to allow the stop fitting to be pushed against the bearing block thus
allowing no side play of the assembly. Tighten the bolt assemblies on the stop fittings.
H. Install the tube support blocks on their support brackets and secure with bolts.
I. Connect the flap return spring to the return chain and/or at the spar housing.
J. Connect the control cable end to the tension chain and secure with bushing, clevis bolt, nut and
cotter pin.
K. Pull the flap handle full back and connect the tension spring. Release the flap handle to the
forward position.
1. Connect the flap control tube to the flap and/or torque tube crank and secure. The bolt and
bushing that connects the control tube to the crank is installed througha hole in the side of the fuselage located
over the torque tube.
2. To install the flap handle with bracket, place the assembly on the floor tunnel and secure with bolts.
3. The flap control cable may be installed by the following procedure:
A. Attach the cable and turnbuckle to the flap handle arm and secure with a new clevis bolt, nut
and cotter pin. Ascertain that the turnbuckle end is free to rotate on the arm.
B. Route the cable through the tunnel and spar housing.
C. Install the cable rub blocks on the aft side of the spar housing and secure with screws.
D. Install cotter pin cable guard over pulley located just ahead of the spar housing in the forward
floor tunnel.
E. Attach the cable end to the tensionchainand secure with bushing, clevis bolt, nut and cotter pin.
If the chain is not installed because of the torque tube assembly being removed, install the assembly as given in
Step 3.
F. Pull the flap handle full back and connect the tension spring to the cable end.
4. lnstall the tunnel cover and secure with screws. Also the tunnel carpet, heat deflectors, and bracket
cover.
5. Install the floor panel and seat belt attachments. Secure with screws and install seats.
RIGGING A N D ADJUSTMENT OF MANUALLY OPERATED WING FLAPS.
1. Place the flap handle in the full forward, flap retracted position.
2. If not previously accomplished, remove the floor panel just aft of the main spar.
3. If required, adjust the flap up stop and step lock, loosen the jam nut of the right torque tube stop
screw, located in the floor opening along the outer end of the flap torque tube, and turn the stop screw to
obtain approximately .60 of an inch between the stop fitting and the bearing block as measured along the top
side of the screw. (Refer to Figure 27-23.)It may be necessary to loosen the adjustment screw of the left stop.
27-51-03
Page 27-43
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 27-23. Flap Step Adjustment
I
4. Check cable tension and adjust if required t o remove all slack. D o not tighten cable t o the point that
the stop screu comes off the stop.
5. Place a 0.I25 of a n inch thick spacer between the right hand stop screw and stop fitting. ij'ith flap4
installed and control rods connected. determine that when down pressure is applied o n t o p o f the flap. it u i l l
not cause the flap t o come d0u.n. If the flap extends (comes down under pressure). turn the stop screus out a
feu. turns until the flap remains in the up-lock position with the spacer inserted. Adjust both stop \ c r r u % .
tighten jam nuts and remove the spacer block.
6 . T o check the up-neutral position of the flaps place a flap rigging tool as shown in Figure 27-25 against
the underside of the riming and flap as close as possible t o the outboard end of the flap without contacting an!.
ri\.ets. (Refer to Chapter 95 for dimensions t o fabricate this tool.)The tool must be positioned parallel with the
u i n g ribs. with the aft end of the tool even with the trailing edge of the flap.
7. With the flap control rods connected between the torque tube crank a r m a n d flaps: check t ha1 the
surface of the u ing contacts the tool at its forward surfaceand at the spacer. and theaft end of the flap contact3
the aft end of the tool. Maintain a light pressure on the underside of the flap t o remove slack in the linkage
u.hile making this check.
8 . If required adjust each flap push rod s o that the chord line o f t h e flap forms a zero degree=IO angle
with the wing chord at the outboard end of the flap. This is the neutral position.
27-51-03
Page 27-44
Revised: August 9. 1984
(J
PIPER AIRCRAFT
PA-?2-301/301 T
MAINTENANCE MANUAL
In the event of wing heaviness during /light, the jlrrp on the side of
the heavy wing can be adjusted down /ram neutral to remedy this
condition by lengthening the control rod. Check the trspection hole
in each rod end to ascertain that them am nrfjicknt threads
remaining and a w i n cannot be inserted through thew holes. Do not
raise the/&p of the other wing above neutral.
9. Measuring from the neutral position obtained from Steps 6, 7 and 8. and maintaining the light up
pressure on the underside of the flap. check flap down travel. which should be 10+,2degreesat first notch. 2 5 2
2 degrees a t second notch and 40 L 2 degrees a t third notch. Readjust the torque tube screw in o r out a s
required. After a n y readjustment of the screw it will be necessary t o review Steps 3 thru 9.
10. Check complete operation of the flaps, and handle and ratchet mechanism. then install all access
covers remo\.ed.
-- NOTE
-
The flap adjustment must be complete bejore starting on aileron
adjustment.
REMOVAL OF ELECTRICALLY OPERATED WING FLAPS. (Refer to Figure 27-24.)
1.
The flap torque tube assembly may be removed by the following procedure:
A . Remove the access plate located between the underside of the aft section of each wing and the
fuselage b!. removing attaching screws.
B. Remove the floor panel located aft of the main spar by removing the center seats, seat belt
attachments and the s c r e w securing the panel. Lift the panel and remove from airplane.
C. The left and right flap control tubes (rods) may be disconnected either at the flaps by remo\ing
the nuts. washers and bolts or at the torque tube cranks (arms) by removing the bolts and washers from the
inner side of each crank. I t will be necessary t o remove the bolt through a hole in the side skin of the fuselage.
The hole is located o\.er the torque tube when the flaps are moved t o their full down position.
D. Disconnect the electrical connections to the limit switches mounted to the torque tube switch
plate.
E. Disconnect the cable ends from the pulley assembly by removing the cotter pins.
F. Disconnect the jack screw actuator from the torque tube bellcrank by removing the nut, washers
and bolt.
G. Remove the tube support bearing blocks by removing the block attachment bolts.
H . Remove the nuts, washers and bolts securing the right and left cranks and stop fittings on the
torque tube.
I. From between each wing and the fuselage. remove the cranks from the torque tube.
J . Disconnect one bearing block from its mounting brackets by removing nuts. washers and bolts.
K . Slide the tube from the bearing block still attached t o its brackets, raise the end and lift it from
the floor opening.
2. The flap control cable may be removed by the following procedure:
A. If the center seats and floor panel have not been removed, remove the seats and the screws
securing the floor panel.
B. Remove the aft heat deflectors on each forward floor tunnel by sliding them far enough t o
release the spring fasteners.
C. Lift the aft section of the tunnel carpet far enough t o remove the screws securing the tunnel cover
and rem0t.e the cover.
21-51-04
Page 27-45
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
D. If not pre\.iously accomplished. remove the cotter pins securing the cable ends to the pullc!
assembl!. on the lorque tube: and the clamps securing the cable housings to the support bracket.
E. Dihconnect the selector lever and cable from the selector lever support bracket mounted on the
aft side of the instrument panel.
F. Remove the cable assembly from the tunnel.
3. The jack screu and motor assembly may be removed by the following procedure.
A. Remove the center seats and floor panels.
B. Disconnect the electrical leads to the motor.
C. If not previously accomplished. remove the nut. washers and bolt securing t h e screw jack
actuator to the torque tube bellcrank.
D. Remove the nut. washers and bolt securing the jack screw t o its mounting bracket. Do not drop
the bushing in the jack screw mounting end.
Figure 27-24. Electrically Operated Flap System
27-51-04
Page 27-46
Added: August 9, 1984
,
. .-
PIPER A I R C R A F T
PA-32-301 1301T
MAINTENANCE MANUAL
INSTALLATION OF ELECTRICALLY OPERATED FLAPS (Refer t o Figure 27-24.)
- NOTE All items covered in the removal instructions may be installed in the
reverse order.
RIGGING A N D ADJL'STMEKT O F ELECTRIC FLAPS
The information to jollow at next revision.
STALL M'ARNING HORN A N D LlFT DETECTOR.
This system consists of two lift detectors which areelectrically connected t o flap position switch and a stall
warning horn. As stalling condition is approached. the lift detector will activate the stall warning horn. The
following ground check can be performed t o determine that the lift detectors are functioning.
The l i f t detectors are located on the leading edge of the left wing a t wing station 174.00. With power
applied. extend flaps t o the 10' flap position. The 0' t o 10' flap position relates only t o the inboard lift sensor.
B!. gent]!- lifting out on the inboard lift detector sensor. the stall warning horn should activate. Lifting out on
the outboard l i f t detector sensor should not activate the stall warning horn. Now position the flap from 25' to
40' and gent]!. lift out on the outboard lift detector sensor. The stall warning horn should activate. The 25' to
40C flap p o s ~ t i o nrelates only t o the outboard lift sensor. Lifting out o n the inboard lift detector sensor should
not a c t i k a ~ ethe stall warning- horn.
LlFT DETECTOR.
REXIOF'AL OF LIFT DETECTOR.
The master battery switch must be ojfprior to pedorming work on
the lijl detector. Place reference marks on holding plate and wing
skin for use when reinstalling.
I . R e m o ~ escrews holding the plate around the tab. The lift detector is fastened to this plate; remo\e the
unit from wing.
2. hlarh the electrical wires and terminals t o facilitate reinstallation. Remove electrical wires from lift
detector; remoLe lift detector from aircraft.
27-91-01
Page 27-47
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-30 1/30 1T
MAINTENANCE MANUAL
INSTALLATIOX OF LlFT DETECTOR.
I. Attach the electrical leads to the appropriate terminals of the lift detector.
2. Position the lift detector with its mounting plate o n the wing. determining that the sensor blade of the
unit drops down freel!.. a n d secure in position with the screws previously removed.
ADJUSTMENT O F LIFT DETECTOR.
The lift detector switch is adjusted a t the factory when the airplane is test flown and should not require an!
further adjustment during the normal service life of the airplane. Should some type of service on the wing
require removing the switch, the following instructions will help in positioning the switch a t the proper
position.
Loosen the t n o Philips head screws: one o n either side of the vane. If the stall warning comes on too late.
m o \ e the switch up. If the stall uarning comes on t o o early. move the switch down. Retighten the screwsafter
making a n adjustments.
-- CA UTION
-
Never try to adjust the switch by bending the vane.
The only way to test the accuracy of the setting is t o fly the airplane into a stall condition and note the
speed at n,hich the stall warning comes on. The stall should be made with the flaps up. power off. I t may be
necessary to make several test flights and alternate adjustments before thedesired setting is obtained. The stall
warning should come on not less than five o r no more than ten miles per hour before the actual stall occurs.
,
455 1
\
1 .375 HEIGHT SPACER IS TO BE IN LlNE WITH AFT SPAR
RIVET LlNE BUT SHOULD NOT MAKE CONTACT WITH
ANY RIVETS
UP NEUTRAL fOCI
OF FLAPS WILL OCCUR WHEN THESE
POINTS MAKE CONTACT WITH WING AND FLAP SKIN
Figure 27-25. Flap Rigging Tool
27-91-03
Page 27-48
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CRlDS 1L5 T H R U 1L24
INTESTIOKALLY LEFT BLANK
SARATOGA
MAINTENANCE MANUAL
CARD 2 OF 3
PA-32-301/301 T SARATOGA
a
Courtesy of Bomar Flying Service
www.bomar.biz
PIPER AIRCRAFT CORPORATION
a
[PART NUMBER 761 7211
2A1
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
a
INTRODUCTION.
This PIPER AIRCRAFT Maintenance Manual is prepared in accordance with the GAMA (General
Aviation Manufacturers Association) format. This maintenance manual is divided into various Groups which
enable a broad separation of contents (Chapters) within each group.
The various Chapters are broken down into major systems such as Electrical Power, Flight Controls.
Fuel, Landing Gear. etc. The SystemlChapten arc arranged more or less alphabetically rather than by
precedence or importance. All SysternIChapters are assigned a number, which becomes the first element of a
standardized numbering system. Thus the element "32" of the number series 32-00-00 refers to the
SystemlChapter on "Landing Gear." All information pertaining to the landing gear will be covered in this
System1Chapter.
The major SystemlChapters are then broken down into Sub-System/Sections. These sections are
identified by the second element of the standardized numbering system. The number "40" of the basic number
series 32-4040 is for the "Wheels and Brakes" ponion of the landing gear.
The individual units within a SubSystemlSection may be identified by a third element of the
standardized numbering system. such as 3240-01. This number could be assigned by the manufacturer to fit
the coverage requirements of the publication.
Example:
CHAPTERlSYSTEM
LAKDIKG GEAR
UB-SYSTEMS
WHEELS AND BRAKES
'
L
NDlVIDUAL UNITS
NOSE WHEEL REMOVAL
This manual does not contain hardware callouts for installation. Hardware callouts are only indicated
where a special application is required. To confirm the correct hardware used, refer to the PA-32-301 /301T
Pans Catalog Pih' 761 720, and FAR 43 for proper utilization.
Introduction
Pmge 1
Issued: Jrnurry 2, 1980
-
PIPER AIRCRAFT
PA-32-301 /301T MAINTENANCE MANUAL
AEROFICHE EXPLANATION AND REVISION STATUS
The Maintenance Manual information incorporated in this set of Aerofiche cards has been arranged in
accordance with the pneral specifications of Aerofiche adopted by the General Aircraft Manufacturer's
Association. (GAMA). The information compiled in this Aerofiche Maintenance Manual will be kept current
by revisions distributed periodically. These revisions will supersede all previous revisions and will be complete
Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set.
Conversion of Aerofiche alpha /numeric code numbers:
First number is the Aerofiche card number.
Letter is the horizontal line reference per card.
Second number is the vertical line reference per card.
Example: 23 16 = Aerofiche card number two of given set. Grid location J 16.
T o aid in locating the various chapters and related service information desired. the following is provided:
I. A complete manual System /Chapter Index Guide is for all fiche in this set.
2 . A complete list of illustrations is for all fiche in this set following SystemiChapter Index.
3. A complete list of Charts is for all fiche in this set following list of Illustrations.
4. A complete list of paragraph titles and appropriate Grid location numbers is given at the beginning of
each Chapter relating to the information within that Chapter.
5. Identification of Revised Material:
Revised text and illustrations are indicated by a black vertical line along the left-hand margin of
the frame. opposite revised. added or deleted material. Revision lines indicate only current revisions
with changes and additions to or deletions of existing text and illustrations. Changes in
capitalization. spelling. punctuation. indexing. the physical location of the material or complete page
additions are not identified by revision lines.
A reference and record of the material revised is included in each chapter's Table of
Contents Effectivity. Thecodes used in the effectivity columns of each chapter are defined as fol1ow.s:
TABLE OF COKTEKTS iEFFECTIVITY CODES
Original Issue:
None
First Revision:
Revision Identification. ( I R Month-Year)
Second Revision: Revision Identification. (2R Month-Year)
All subsequent revisions will follow with consecutive revision numbers
such as 3R. 4R. etc.. along with the appropriate month-year.
Added Subject:
Revision Identification. (A Month-Year)
Deleted Subject: Revision Identification. ( D Month-Year)
lntroduction
Page 2
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-361/301T
MAINTENANCE MANUAL
6. Revisions to Maintenance Manual 761 721 issued January 2, 1980 an a s
follows:
Ufectivity
Publication Date
Aerofiche Card Effectivity
January 2, 1980
May 21, 1980
August 19, 1980
September 23, 1981
February 19, 1982
August 23, 1982
August 1 1. 1983
August 9. 1984
August 15, 1985
April 30,1986
July 30, 1986
September 20, 1986
May 12, 1987
1.2 and 3
1,2ad3
I, 2 and 3
1 , 2 and 3
1, 2and 3
1, 2and 3
1, 2 and 3
1,2and 3
3
1
1
1
1
The date on Aerofiche cards must not be earlier than the date noted for the respective card effectivity. Consult
the latest Aerofiche card in this series for current Aerofiche card effectivity.
This publication contains material revised as of August 15, 1985
(with four interim revisions effective -April 30, 1986, July 30, 1986,
September 20, 1986 and March 16, 1987).
INTERIM CHANCE
Revisions appear in chapter 5 of clrd 1. There are no other changes
in this mrintemnce manml. P k a r discard your current card 1and
replace it with this revisld om. DO NOT DISCARD CARDS 2 or
3.
Introduction
Page 3
Interim Revidon: March 16, 1987
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
VENDOR PUBLICATIONS.
ENGINE:
Overhaul Manual =
-
AVCO LYCOMING OVERHAUL MANUAL
DIRECT DRIVE ENGINE P'h' 60294-7
Avco Lycoming Division
W illiamspon. Pa. 17701
AVCO LYCOMING - P I N PC-102
P a n s Catalog =
Avco Lycoming Division
W illiamspon. Pa. 17701
Operators Handbook = AVCO LYCOMING 10-540 and TIO-540
SERIES AIRCRAFT ENGINES - P 'ki 60297-10
Avco Lycoming Division
Williamsport. Pa. 17701
PROPELLER:
O\*erhaulInstructions =HARTZELL C O M P A C T CONSTANT S P E E D
and FEATHERING PROPELLER - P h: 117-D
Hartzell Propeller Inc.
Piqua. Ohio 45356
MAGNETOS.
Installation. Operation
and M a ~ n ~ e n a n c e
Instructions =
D-2000 and D-2200 SERIES MAGNETO
IGNITION SYSTEM - P h: L-928
Bendix Electrical Components Division
Sidne!. JVew York 13838
AC'TO FLIGHT:
-
CENTURY 41 AUTO PILOT
EDO-AIRE Mitchell
P.O. Box 610
Mineral Wells. Texas 76067
Introduction
Page 4
Revised: August 9. 1984
-
PIPER AIRCRAFT
PA-32301 /301T
MAINTENANCE MANUAL
PIPER PUBLICATIONS.
COMMUNICATIONS:
Removal. 1nstallation
and Maintenance
761 502 AutoControl 111 B Service Manual
instructions =
761 481 AutoFlitc 11 Service Manual
753 77 1 Pitch Trim Service Manual
Radio Service and
Maintenance Manual = 76 1 7 13 Avionics Wiring Diagram Service Manual
Vol. 1 and Vol. 11 (1979)
REPAIRS:
A.B.S. Thermoplastic
Landing Gear Wheel
and Strut Fairing
Repair Instructions = 761 708\' A.B.S. Thermoplastic Landing Gear
Wheel and Strut Fairing Repair Instruction Manual
PARTS CATALOG =
PA-32-30 1 30 1 T
761 720
PERIODIC INSPECTION
REPORT FORM =
230 1046
PA-32-301 301 T
P R O G R A M M E D INSPEC761 747
TION M A S C A L =
PA-32-301 301T
Introduction
Page - 5
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
C A M A SYSTEMICHAPTER INDEX GUIDE
SYST
CHAP
SUB-SY ST
SECTION
TlTLE
AEROFICHE
G R I D NO.
AlRWORTHlNESS
T l M E LlM1TS;MAINT C H E C K S
DlMENSlONS A N D AREAS
LlFTlNG A N D SHORING
LEVELlNG A N D W E l G H l N G
T O W l N G A N D TAXIING
PARKlKG AND MOORlNG
REQUIRED PLACARDS
- LUBRICATIOK
STANDARD PRACT - AlRFRAME
SERVlClKG
EKVlRONMEKTAL SYSTEM
AUTOFLlGHT
COM MUKlCATlOXS
ELECTRlCAL POWER
EQUIPMEKT 'FURNlSHlKGS
FLlGHT COKTROLS
FUEL
2A18
LANDIKG GEAR
2B17
LlGHTS
2D5
KAVlGATlOK & P I T O T , S T A T l C
2D17
OXYGEN
2E6
Introduction
Page 6
-
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301
/301T
MAINTENANCE M A N U A L
GAMA SYSTEMICHAPTER INDEX GUIDE (cont)
AEROFICHE
G R l D NO.
SYST
CHAP
SUB-SY S T
SECTION
37
VACUUM
2F4
39
ELECTRICAL
2F14
51
STRUCTURES
TITLE
DOORS
STABlLIZERS
56
WINDOW'S
57
WINGS
61
PROPELLERS
70
S T A K D A R D PRACTICES - ENGINES
POWER PLAKT
ENGINE FUEL SYSTEM
1Gh'lTlOh'
ENGINE INDlCATlh'G
EXHAUST
OIL SYSTEM
STARTlNG
TURBINES
C H A R T S A K D WIRING D I A G R A M S
SPECIAL P U R P O S E EQUIPMENT
introduction
-
Page 7
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS
F I G U R E KO.
SUBJECT
G R I D KO.
Three View of PA-32-30 1
Three View of PA-32-301T
Station Reference Lines (PA-32-301)
Station Reference Lines (PA-32-301T)
Access Plates and Panels
Jacking
Leveling Airplane
Weighing
Placards and Decals
Fuel Filter Bowl and Screen
Servicing Points
Main Gear Oleo Struts (Cut-Away View)
Lubrication C h a n (Landing Gear. Main)
Lubrication C h a n (Landing Gear, Nose)
Lubrication C h a n (Control System)
Lubrication C h a n (Air Conditioning Condenser)
Lubrication C h a n (Cabin Door, Baggage Door
and Seat)
Lubrication C h a n (Power Plant, Propeller and
Control Pivot Points)
Lubrication Chart (Back-Up Extender and Fuel Selector)
Torque Wrench Formula
Method of Installing Rod End Bearings
Cherrylock Rivet Removal
Hose Line Markings
Flareless-Tube Fittings
Maximum Distance Between Supports for Fluid Tubing
Cabin Heater. Defrosters and Fresh Air System
(PA-32-30 1 )
Cabin Heater. Defroster and Fresh Air System
(PA-32-301T)
Air Conditioning System Installation (Typical)
Service Valves
Test Gauge and Manifold Set
Manifold Set Operation
Leak Test Hookup
Evacuation Hookup
Charging Stand
Charging Hookup
Compressor and Fabricated Oil Dipstick
Compressor and Alternator Belt lnstallation
Magnetic Clutch
Condenser Air Scoop Installation
Expansion \'al\.e
Components lnstallation
Air Conditioning Wiring Schematic (Earl!. Models)
Air Conditioning Wiring Schematic (Later Models)
lntroduction
Page 8
-
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
SUBJECT
F l G U R E KO.
G R I D KO.
Emergency Locator Transmitter Schematic
(h'arco)
E LT Portable Folding Antenna (Narco)
ELT Using Fixed Aircraft Antenna (Karco)
Avionics Master and Emergency Switch Circuit
Exploded View of Alternator Prestolite
Lamp-Bank Load
Removal of Slip Ring End Bearing
Removal of Rectifier
Removal of Drive End Head
Removal of End Head Bearing
Testing Rotor for Ground
Testing Rotor for Shorts
Installation of Bearing
Installation of Rectifier
Terminal Assembly Prestolite
Slip Ring End Bearing Assembly
Testing Alternator
Brush l nstallation
Internal Wiring Diagram
Alternator Exploded View - Ford
Rear i'iew Terminal Identification
Stator Core and \'indings
Rectifier Assemb1)lnternal Relationship of Alternator Components
Rectifier Ground and Positive Diode Test
Stator Ground and h'egative Diode Test
Field Circuit Open or Ground Test
Alternator Housing Disassembly
Rear Housing Components
Front Housing Disassembl!.
Front Housing Components
Rotor Continuit!, Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
-
-
Introduction
Page 9
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301/301~
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (eont)
FIGURE KO.
SUBJECT
GRID NO.
Diode Testing
Front Housing Assembly
Rear Housing Bearing and Brush Assembly
lnstallation
Rear Housing Components
Housing Assembly
Alternator lnstallation Ford
Seat Back Lock
Rod End lnstallation Method
Control Column Assembly
Aileron Controls
Aileron Rigging
Bellcrank Rigging Tool
Aileron Rigging Tool
Aileron Rudder Interconnect
Rudder Controls
Rudder Rigging Tool
Rudder Travel Adjustments
Rudder Rigging
Clamping Rudder Pedals
Rudder Trim Control
Rudder Steering Pedal Assembly
Stabilator Controls
Stabilator Rigging
Stabilator Travel Adjustments
Methods of Securing Trim Cables
Stabilator Trim Controls
Wrapping Trim Barrels
Stabilator Rigging Tool
Flap Controls
Flap Step Adjustment
Flap Rigging Tool
Fuel System (PA-32-301)
Fuel System (PA-32-301T)
Fuel Cell lnstallation
Installation of Locking Fuel C a p
Fuel Filter
Fuel Gauge
Main Gear Oleo Strut Assembl)
Main Gear Installation
Kose Gear Oleo Strut Assembly
-
Introduction
Page 10
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
L I S T O F ILLUSTRATIONS (cont)
F l G U R E KO.
SUBJECT
Nose Gear lnstallation
Clamping Rudder Pedals in Neutral Position
Rudder Pedals a t Neutral Angle
Main Wheel Assembly
Kose Wheel Assembly
Brake Assembly
Removal and lnstallation of Anchor Bolts
Brake Disc Minimum Thickness
Brake System lnstallation
Brake Master Cylinder (HandIParking Brake)
Toe Brake lnstallation
Brake Cylinder (10-30) (Toe Brake)
Brake Cylinder ( 17000) (Toe Brake)
Landing Gear Fairing lnstallation
Strobe Light Connections
Pitot-Static System lnstallation
Fixed Oxygen System lnstallation
Test Apparatus for Testing Oxygen System
Oxygen Tubing lnstallation
lnstallation of Swagelock Fittings
Oxygen Cylinder a n d Regulator Assem bl)
O x ~ g e nSystem Recharge Valve lnstallation
Oxygen Pressure Gauge lnstallation
Oxygen l nstallation (Portable)
Skin Material and Thickness
Surface Scratches. Abrasions o r Ground-in-Dirt
Deep Scratches. Shallow Kicks and Small Holes
Mixing of Epoxy Patching Compound
Welding Repair Method
Repairing of Cracks
Various Repairs
Repair of Stress Lines
Repair of Impacted Damage
Snubber lnstallation
Empennage Group
Stabilator Balancing
Rudder Balancing
Windshield lnstallation (Typical)
Introduction
Page 11
Revised: August 11, 1983
-
PIPER AIRCRAFT
I
PA-32-301/301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
I
,
F I G U R E KO.
SUBJECT
G R I D KO.
Side Window Installation, Single Pane (Typical)
Wing lnstallation
Aileron and Flap lnstallation
Aileron Balance Configuration
Typical Nicks and Removal Method
Propeller lnstallation (PA-32-301)
Three Blade Propeller lnstallation (PA-32-301)
Propeller lnstallation (PA-32-3OIT)
Three Blade Propeller lnstallation (PA-32-30 1 T)
Propeller Governor
Engine lnstallation (PA-32-301)
Engine Mount lnstallation (PA-32-301T) (Dynafocal)
Engine Mount Installation (PA-32-301T) (Lord Mounts
Fuel Injector
Schematic Diagram of R S A Fuel Injection System
Fuel-Air Bleed Kozzle
Adjustment of Engine Controls
Height of Spring in Distributor Block Tower
Contact Points
Engine Timing Marks
T ~ m i n gLight Connected t o Magneto
Timing Marks on Magneto Rotor
Painted Tooth Centered in Timing Window
T ~ m i n gMark on Rotor Aligned with Pointer
T ~ m i n gLight Connected t o Magento and Breakers
Cam End V ~ e wof Magneto
Removing Impulse Coupling
Checking Flyweight to Stop Pin Clearance
Stop Pln lnstallation Dimension
Checking Flyweight Axial Wear with Drill Shank
Checking Flyweight Radial Wear with Gauge
Points of Coupling Body Wear
Acceptable and Deformed Coupling Springs
Checking Impulse Coupling for Magnetization
Orientation of Spring in Coupling Body
Lifting Inner End of Spring
Checking Harness Lead Continuity
Checking Harness Lead insulation Resistance
Modified Pliers
Removing Spring From Lead Assembly
Assembly Tool
Using Assembly Tool
Ferrule Postioned Under Braid
Ferrule Seating Tool
Position of 11-8627 Kit and Contact Spring at
Start of lnstallation
introduction
Page 12
-
Revised: August 11, 1983
i
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
a
LIST OF ILLUSTRATIONS (cont)
FlGURE NO.
GRID S O .
SUBJECT
Position of 1 1-8627 Kit and Contact Spring
After Installation
Lubricating Sleeve
Lubricating Ferrule Shoulder
Removing Spark Plug Frozen t o Bushing
Ignition Switch Wire Positions
Exhaust System Inspection Points
Exploded View of Gear Reduction Staning Motor
Turning Staning Motor Commutator
Testing Motor Armature for S h o n s
Testing Motor Fields for Grounds
K o-Load Test Hook-U p
Stall-Torque Hook-Up
Turbocharger Installation
Tire Balancer Fixture
Orifice Replacement Tool
Fabricated Tool for Baggage Door Lock
Retainer Ring Tool
Fabricated Aileron Bellcrank Rigging Tool
Fabricated Rudder Rigging Tool
Fabricated Aileron and Flap Rigging Tool
Fabricated Stabilator Rigging Tool
Control Surface Balancing Tool
Refer to Card 3, Grid No. 3 D l l for Electrical Schematic Index.
Introduction
Page - 13
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
LIST OF CHARTS
C H A R T KO.
SUBJECT
G R I D NO.
Leading Particulars and Principal Dimensions
Thread Lubricants
Type of Lubricants
Hose Clamp Tightening (Initial Installation)
Blower System Wire Color Codes
Troubleshooting (Air Conditioner)
Troubleshooting (Air Conditioning System)
Temperature Pressure
Aluminum Tubing Torque
System Vacuum Chart
Compressor Oil Charge
Troubleshooting (Alternator)
Troubleshooting (Batter!)
Alternator Specifications (Prestolite)
Alternator Belt Tension (Prestolite)
Hydrometer Reading and Battery Charge Percent
Electr~calSystem Component Loads
Troubleshooting (Surface Controls)
Cable Tension Vs. Ambient Temperature
Troubleshooting Chart (Fuel System)
Fuel Cell Repair Equipment Lists
Sender Fuel Quantity Gauge Tolerances
Troubleshooting Chart (Landing Gear)
h o s e Gear Alignment Tolerances
Electrical System Troubleshooting
Troubleshooting (Rate of Climb Indicator)
Troubleshooting (Altimeter)
Troubleshooting (Airspeed Tubes and Indicator)
Troubleshooting (Gyro Horizon Indicator)
Troubleshooting (Directional Gyro Indicator)
Troubleshooting (Magnetic Compass)
Troubleshooting (Turn and Bank Indicator)
Troubleshooting (Oxygen System)
Oxygen System Component Limits (Fixed)
Filling Pressures for C e n a i n Ambient Temperatures
Oxygen System Component Limits (Portable)
Troubleshooting (Vacuum System)
L ~ s tof Materials (Thermoplastic Repair)
Propeller Specifications (PA-32-301)
Propeller Specifications (PA-32-301T)
Engine Troubleshooting Chart
Troubleshooting (Magneto)
Coupling Torques
introduction
-
Page 14
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE M A N U A L
LlST OF CHARTS (cont)
C H A R T KO.
SUBJECT
G R I D NO.
Troubleshooting (Manifold Pressure Indicator)
Troubleshooting (Tachometer)
Troubleshooting (Engine Oil Pressure Gauge)
Troubleshooting (Oil Temperature Indicators)
Troubleshooting (Exhaust Gas Temperature
Gauge) (Alcor)
Troubleshooting (Cylinder Head Temperature Gauge)
Troubleshooting (Staner)
Starting Mot or Specifications
Troubleshooting (Turbocharger)
Tube and Hose Assembly Torque
Recommended Kut Torques
Decimal Conversions
Con\.ersion Charts
List of Consumable Materials
Electrical N'ire Coding
Electrical Symhols
lntrodurtion
Page
- 15
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE M A N U A L
THIS PAGE lNTEKTlONALLY LEFT BLANK
CHAPTER
FUEL
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
--
-
--
-
-
CHAPTER 28 FUEL
TABLE OF CONTENTSJEFFECTIVITY
CHAPTER
SECTlON
SUBJECT
28-00-00
28-0 1-00
SUBJECT
GRlD
NO.
EFFECTIVITY
GENERAL
Troubleshooting
STORAGE
lnboard Fuel Tanks
lnspection and Repair of Aluminum Fuel
Tanks (Inboard)
Remo\.al of lnboard Fuel Tank
lnstallation of lnboard Fuel Tank
Outboard Fuel Cell
Removal of Outboard Fuel Cell
lnstallation of Outboard Fuel Cell
Molded hipple Fittings
Fuel Cell Compartment
Cleaning of Fuel Cells
lnspection of Fuel Cells
Handling and Storage of Fuel Cells
Repair of Fuel Cells
Handling of Repair Materials
Repair Procedures of Goodyear Vithane Fuel Cells
Repair Limitations of Fuel Cells
Repair Patch (Heat Cure Method)
Repair Patch (Air Cure Method)
Accessory Replacement
Defect Repairs of Fuel Cell
Testing Fuel Cells
lnspection of Fuel S!lstem
Locking Fuel Cap
Disassembl!~ of Locking Fuel C a p
Assembl! of Locking Fuel Cap
DISTRIBUTION
Fuel Selector Valve Operation
Removal of Fuel Selector Valve and Filter
Cleaning Filter Assembly
lnstallation of Fuel Selec~orValve and Filter
Cleaning Fuel System
Electric Fuel Pump
Remo\,al and lnstallation of Electric Fuel P u m p
ISDICATING
Fuel Quantity Sender Unit
Fuel Quantit! Sender Gauge Check (Installed)
2815
2815
2815
-
28 Cont./Effec.
Page
-1
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
The fuel system consists of two interconnected tanks in each wing. having a combined capacity of 53.5
U.S. @allons.for a total capacity of 107 U.S.gallons. The inboard tanks become an integral part of the wing
surface when installed. Fuel flow is indicated on the gauge located in the instrument panel. A fuel quantity
gauge for each wing system is also located in the instrument panel, and indicates the amount of fuel remaining
as transmitted by the electric fuel quantity sending units located in the wing tanks. An exterior sight gauge is
installed in the inboard tank of each wing so fuel quantities can be checked an the ground during the preflight
of the airplane.
Fuel is drawn through a finger screen located in the inboard fuel tank and routed t o a three position fuel
selector valve and filter unit which is located aft of the main spar. The valve has 'OFF." "LEFT" and
"RIGHT" positions which are remotely selected by means of a torque tube operated by a handle located in the
pedestal. The handle has a spring loaded detent to prevent accidental selection to the "0FF"position. From
the selector valve the fuel goes t o the electric fuel pump which is also mounted aft of the main spar and then
goes forward t o the engine driven fuel pump which forces the fuel through the injector unit into the engine.
Refer to Figure 28-1 or 28-2 for layout and relationship of the fuel system and components.
Electrical and mechanical troubles of the system are found in Chan 2801. When troubleshooting. check
from the power supply to the items affected. If no trouble is found by this method. the trouble probably exists
inside individual pieces of equipment: they may then be removed from the airplane and an identical unit or
units. tested and known to be good. installed in their place.
CHART 2801. TROUBLESHOOTING (FUEL SYSTEM)
Trouble
Failure of fuel to flow.
Cause
Remedy
Fuel line blocked.
Flush fuel system.
Fuel vent cap blocked.
Check and clean vent
hole in cap.
Mechanical or electrica;
fuel pump failure.
Check and replace if
necessary.
Fuel selector valve
in improper position.
Reposition as required.
Check for obstructions
in the fuel selector
leverage mechanism.
Damaged fuel selector
valve.
Replace fuel selector
valve.
I
i
Page 28-01
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
C H A R T ZROI. TROUBLESH-OOTING (FUEL SYSTEM) fcont)
Trouble
Fuel quantity gauge
fails to operate.
S o fuel pressure
indication.
Lower pressure or
pressure surges.
b
Cause
Remedy
Broken wire.
Check and repair.
Gauge inoperative.
Replace gauge.
Fuel sender float
panially o r completely
filled with fuel.
Replace sender.
Circuit breaker open.
Check and reset.
Float and arm assembly
of fuel sender sticking.
Chcck.
Bad ground.
Check for good contact
at ground lip or rear
of gauge.
Fuel selector valve
stuck.
Check fuel selector
valve.
Fuel tanks empty.
Check fuel tanks
and fill.
Defective gauge.
Replace gauge.
Fuel selector valve
in improper position.
Reposition fuel selector
valve lever.
Obstruction in inlet
side of pump.
Trace lines and locate
obstruction.
Air in line t o pressure
gauge.
Bleed line.
28-0 1-00
Page 28-02
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
b
FUEL FLW/PRESSE
C U E
FUEL SELECTOR
FUEL
FUEL
CELL
FUEL
CELL
FUEL OUINTITY
\
O~USLS
VENT
\
C
n
h
Figure 28- I . Fuel System (PA-Jts3Gl)
28-01-00
Pate 28-03
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2866
FUEL INJECTOR
FLOW DlVlDERS (21
FUEL
NOZZLES
(6
I
i
R
I
1I
-
I
M A N I F O L D PRESSURE
AND FUEL FLOW
GAUGE
I
I
I
i
I
F U E L SELECTOR
VALVE
VENT
FUEL QUANTITY GAUGES
VENT
28-01-00
Page 28-04
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
STORAGE.
( INBOARD FI'EL TANKS.
INSPECTION AND REPAIR O F ALUMINUM FUEL TANKS (INBOARD).
Fuel tanks should be completely drained before inspection. (Refer t o Draining Fuel Systems. Chapter
12.) Each tank should be carefully inspected for signs of leaks a s indicated by telltale stains. In the e\ent a fuel
leak is detected. the fuel tank must be removed. and repaired as follows:
I. The tanks should be sloshed in accordance with instructions provided o n each can of Randolph
Sloshing Sealer 802. (M1 L-L-6047B). Piper P N 757 572. One gallon of sealer is required for each tank. When
sloshing. the finger strainer. fuel sender unit. sight gauge and drain valves must be remo\.ed before proceeding.
Seal all openings. After sloshing. check for leaks using a water and soap solution a n d apply 1.5 pounds of air
pressure.
2. I f the tank being inspected has previously been sloshed. the interior of the tank should be inspected
for signs of peeling or chipping sealer. Particular attention should be given the area around the filler neck as a
result of the metal nozzle of the gas filler hose nicking the sealer. This inspection can best be accomplished
using a mirror and inspection light through the filler neck. If peeling and o r chipping has occurred and
separated material is found. the tank should be sloshed as explained in Step I.
3. After sloshing. reinspect as outlined in Step 2 at intervals of 100 hours.
Thefuel tank should be replaced if it has been damaged to the extent
it cannot be repaired by above procedures.
Seal all pipe threads with medium weight "Tite Seal" gasket and
joint sealing compound. (Rejer to Chart 9105for manujacturer.) To
prevent sealant from entering fuel system, do not qpply to first two
threads.
REMOVAL OF INBOARD FUEL TANK.
1. Remo\.e the access panels located inboard and outboard of the fuel tank on the underside oft he wing.
2. With fuel completely drained from the tank and working through the access hole in the wing
undersurface. loosen the clamps on the two inch diameter fuel tank interconnect line and the 3 4 inch fuel vent
interconnect line and remove the lines from the fuel tank.
3. Working through the access hole on the inboard side of the fuel tank (undersurface of wing).
disconnect fuel line.
4. Remove screws from around the perimeter of the tank. Carefully pull the tank away from the wing far
enough to gain access t o the fuel sender unit and disconnect the wire from the sender.
5. The tank is now free t o be removed.
INSTALLATION OF INBOARD FUEL TANK.
I. Position fuel tank in its recess in the wing. Connect fuel sender wires. Slide tank completely into
position and secure with screws around its perimeter.
28-1 1-03
Page 28-05
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
2. Using access hole located on underside of wing. slide hose on interconnecting fuel line and fuel \ent
line into position. Insert blade of screwdriver through hole in rear outboard corner of fuel tank skin and
tighten clamps t o torque specified in Figure 28-3.
3. Connect fuel line on inboard side of tank.
4. Fill fuel tanks and check for leaks. unrestricted fuel flow. accurate sender indications on fuel quantity
gauge. and that ground wire is securely attached t o interconnecting fuel line. fuel vent line and wing rib at w.ing
station 88.75.
I
OUTBOARD FL'EL CELL.
REMOVAL OF OUTBOARD FUEL CELL. (Refer t o Figure 28-3.)
1.
Drain the fuel cell as described in Chapter 12.
2. Remo1.e the access co\,ers (wing station 1 1 1.8. 165.5 and 129.3) from the bottom of thewing.
3. Remo\e the twel\.e screws.securing the fuel cap adapter assembly t o the upper wing surface (wing
station 140.09) and remove the adapter assembly.
4. Remo\.e the four screws securing the fuel cell and the nut ring and gasket t o the top of the w.ing and
remo\.e the nut ring and gasket.
5. Utilizing the access opening at wing station 165.5. loosen the two clamps which secure the fuel \en1
line and fuel \ent assembly in the fuel cell nipple.
6. Carefully separate the fuel vent line from the fuel cell nipple.
7. Reach in the fuel cell and remo\.e the fuel vent valve assembly from the fuel cell nipple.
8. Utilizing the access opening at wing station I 1 1.8 loosen the clamps securing the fuel cell t o the upper
and lower fuel interconnecting lines and separate the interconnecting lines from the fuel cell.
9. Working through the access opening at wing station 129.3 (lower wing surface). disconnect the
electrical wire from the fuel sender unit terminal. Remove the five bolts securing the fuel sender unit and
remo\e the sender unit from the fuel cell.
10. Insert your arm between the fuel cell and the t o p of the wing and separate the velcro strips w hich hold
the fuel cell in place.
I I . Fold the fuel cell into a manageable form and withdraw the fuel cell through the access opening a t the
t o p of the wing.
INSTALLATION OF OUTBOARD FUEL CELL. (Refer t o Figure 28-3.)
I. Inspect the cell compartment as explained in the paragraph "Fuel Cell Compartment."
2. D o not use sharp tools such as screwdrivers. files. etc.. for installation purposes.
3 Roll the cell into a shape and size which can be inserted through the access opening of the cell
compartment.
4. Place the cell within the cell compartment. Unroll thecell and establish correct relationship of the cell
t o the compartment.
5. Secure the cell by pressing the vclcro strips of the fuel cell against the velcro strips of the cell
compartment.
6. Using the appropriate access opening in the bottom of the wing. install the fuel sender unit as shown
in Figure 28-3. View "A."
7. Reaching into the fuel cell. place the fuel vent valve assembly in place in the fuel cell vent nipple.
Secure with a clamp installed through the appropriate access opening in the bottom of the wing (torque 12- 16
in.-lbs.).
28- 12-02
Page 28-06
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 130 1T
MAINTENANCE MANUAL
8. Insert the fuel vent line one inch into the fuel a l l vent nipple and secure with clamp (torque 12- 16
in.-lbs.).
9. Insert the fuel interconnect lines into the appropriate fuel cell openings and secure with clamps.
Torque the 3 , 4 inch fuel vent interconnect clamp (#12HL) 15-20 in.-lbs. and the 2 inch fuel tank interconnect
clamp (#32HL) 30-35 in.-lbs.
10. Align the holes of the cork gasket, fuel cell and nut plate and secure with four screws (torque 12-15
in.-lbs.).
I I . Wipe the inside of the cell clean of aU din and foreign material with a clean soft lint-free cloth and
inspect for cleanliness.
12. Place a new gasket and the fuel cap adapter assembly into position and align the holes. Coat the
threads of the twelve attaching screws with PR1422 CL2 sealant, install the screws and torque 30 in.-lbs.
Remove excess sealant with M.E.K.
3 Fill the fuel tanks and check for leaks, unrestricted fuel flow and proper fuel level indication.
14. Install access covers.
MOLDED NIPPLE FITTINGS.
The molded nipple fitting is a lightweight fitting developed for ease in installation. To receive the best
service from this type fitting, it is necessary to exercise certain precautions at the time of installation.
1. Unless otherwise specified. insert tubing into the fitting until theend is flush with the inside edge of the
nipple.
2. The hose clamp must clear the end of the fitting by 114 inch where possible.
3. Locate the hose clamp on the fabric reinforced area of the nipple.
4. Do not use scaling paste or gasket compound.
5. Use lightweight motor oil to facilitate insenion of tubing into nipple.
FUEL CELL COMPARTMENT.
1. Clean compartment thoroughly of all fittings, trimmings, loose washers, nuts. bolts and etc.
2. Round off all sharp edges. Where this is not possible tape over all sharp edges or rough rivets
3. Inspect companment for cleanliness and condition prior to installation of fuel cell.
CLEANING OF FUEL CELLS.
1. New fuel cells, if kept in their shipping containers, should not require cleaning prior to installation.
However, if a cell should become dirty it should be cleaned with soap and wann water to remove any foreign
material.
2. Prior to removal, a used cell should be drained, purged with fresh air and swabbed out to remove all
traces of fuel. Upon removal the cell should be cleaned thoroughly with soap and warm water.
INSPECTION OF FUEL CELLS.
1. When installed in an airplane a fuel cell should be inspected during regularly scheduled airplane
inspections.
2. Inspect the interior of each tank for cracking, porosity or other signs of deterioration.
28-12-06
Page 28-07
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
112 HL
- 15 to 20 in.-lbs
__--12-15 IN. LBS.
1 FUEL CELL
2. FUEL SENDER UNIT
7 NEOPRENE GASKET
8 CORK GASKET
9 FUEL CELL
10 NUT RlNG
12 FUEL VENT VALVE ASS'Y
13. CLAMP ( I 1W L I
15. FUEL VENT LINE
16 NUT RING
17. FUEL CELL
19. FUEL CAP ADAPTER ASSY
22 FUELTANK
23 CLAMP f*32HL)
24 CLAMP (+I 2HL)
AlTACHMENT
Figure 28-3. Fuel Cell Installation
28-1 2-06
Page 28-08
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
3. Inspect nipple fittings utilizing the fingernail test as follows:
A. Using the fingernail. attempt to scrape the rubber off the nipple fitting. If the rubber has not
degraded. the fingernail will glide across the rudder without damage to the rubber. If an unsatisfactor)
condition exists. the fingernail will dig into the rubber.
B. Deteriorated rubber has consistency of either a n gum or chewing gum. Usually it will have
changed from a light tan color to a dark reddish-brown or greenish color depending upon the color of fuel
used.
4. Any tank found seeping or with soft nipples should be replaced.
HANDLING AND STORAGE OF FUEL CELLS.
I . The fuel cells should not be removed from the shipping container until the time of installation.
2. Upon removing the fuel cell from the shipping container. inspect the cell for damage due to
crating o r removal from crate.
3. Fuel cell nipple fittings are not to be used as handholds. D o not drag fuel cells and stack only in
original shipping containers.
4. Prior to storing used fuel cells. clean with soap and warm water.
5 . Fold fuel cells smoothly and loosely with a minimum number of folds. Protective wadding should be
placed between the folds.
6. Store fuel cells in a dry area protected from sunlight. Recommended storage temperature is 70" F.
-- CAUTION
-
Should the temperature be below 70" F move the cells to a warmer
location.
REPAIR OF FUEL CELLS. (Refer to Chart 2802.)
The following is a repair procedure recommended for field repair of fuel cells constructed of Goodyear
Vithane material. There are two methods by which these repairs may be accomplished. One method is by heat
cure; the other is air cure. The end result of either repair isa neat. permanent repair. The heat repair allows the
cell t o be cured and ready for reinstallation in two hours: while theair cure method requires that the cell not be
moved for 72 hours during the air cure period.
-- NOTEAir cure repairs are to made at a room temperature of
approximately 750 F. For each 10" drop in temperature, add 20
hours cure time. For instance, iJtheroom temperaturereads 6 5 ,air
cure lor 92 hours instead of 72 hours.
HANDLING OF REPAIR MATERIALS.
1. .All materials are to be protected from d i n contamination. sunlight. and excessive heat o r cold while
in storage. Containers are to be tightly capped and stored a t a temperature of 70°F.
2. The repair code 80C27 referred to in this text is prepared immediately prior to use by mixing repair
cement 90C27 (pint can with 320 gms) with cross-linker 80C28 (4 oz. bottle with 81cc).
-
CAUTION
-
8K27 repair cement requires thorough mixing to obtain'jull adhesive values.
28- 1 2-09
Page 28-09
Revised: August 11. 1983
PIPER AIRCRAFT
P.4-32-301/301T
MAINTENANCE MANUAL
3. Repair cement has a pot life of 20 minutes after mixing. The unmixed 80C27 and 80C28 have a sheli
life of six months from the date of packaging.
A11 containers for cements and solvents should be properly
identifed.
REPAIR PROCEDURES OF GOODYEAR VITHANE FUEL CELLS.
The repair of Coodyear Vithanejuel cells is restricted to authorized
personnel. Authorized personnel are those who have been certijied
and trained by Goodyear representatives, or those who have
received their training from persons who have been certified and
trained b y Goodyear representatives.
REPAIR LlMlTATlOlVS OF FUEL CELLS.
Repair limitations are a s follou~s:
I. FT-192repair fabric is for repair of simple contours only. Patches referred to in this tes1 arc' o i thi,
materia 1.
.
Inside patches are to lap defect edges a minimum of 1.0 inches in each direction.
3. Outside patches are to lap defect edges .25 t o .SO inches inside patches.
4. Outside patches are to be applied and cured prior t o applying a n inside patch.
5 Blisters between inner liner and fabric larger than .25 of a n inch in diameter require a n outside and a n
inside patch.
6. Separations between la!.ers or plies larger than .50 inch in diameter require an outside and inside
patch. Holes and punctures require a n outside and inside patch.
7. Slits or tears up t o 6.0 inches maximum length require a n outside and inside patch.
8. External abraded o r scuffed areas without fabric damage require an outside patch onl!.
9. A loose edge may be trimmed provided a .SO inch minimum lap o r seam is maintained.
10. Air cure repair patches are to remain clamped and undisturbed for 72 hoursat a room temperarure of
approximatel!. 75' F.
For each 10' drop in temperature from 750 F, add 20 hours cure
time. For example: at 650 F, cure for 92 hours.
I I . All heat cured patches are ready for use when cool.
12. Fitting repairs are confined to loose flange edges. seal surface rework and coat stock.
I . The maximum number of heat cure repairs in the same area is four.
-- NOTE
-
Any damage not covered by the above should be returned to: The
Goodyear Tire & Rubber Company, Rockmart, Georgia 30153,for
repair.
28-12-11
Page 28-10
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
C H A R T 2802
--
FUEL CELL REPAIR EQUIPMENT LISTS
Repair Kit. Goodyear P a n No. 2Fl-3-37813
GROUP I MATERIALS
80C27 R e p a ~Cement
r
80C28 Cross-Linker
Methylethylketone
FT-192 Repair Fabric
AP368 Manual
8
8
2
2
Pint cans 320 gms in each
14 oz bottles 81 cc in each
1 pint cans
Sheet 12" x 12"
I
GROUP 11 MATERIALS
The following equipment is necessary to perform the repair.
Group 11 equipment will be furnished at additional cost. if ordered
by customer.
Foam Rubber Cloth Sheet. 1 4" x 12" x 12"
Paint Brush. 1 inch wide
Aluminum Plates. 1 4" x 6" x 6"
Measuring Cup (250 ml)
Cellophane (Sheet 12" x 24")
2
2
4
1
2
KOTES
Accessories
- order per individual cell requirements.
Phenol plates. phenol plate assemblies and phenol test equipment
can be ordered as required from cell manufacturer.
Alodine 1200 to be ordered a s required from cell manufacturer.
Cure Iron (Set 240° F) Optional.
i
28-12-1 1
Page 28-1 1
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-91/301T
MAINTENANCE MANUAL
REPAIR PATCH (HEAT CURE METHOD).
1. Prepare the exterior cell wall and exterior patch first. Cut a repair patch from FT-192 materialto the
size required to insure a proper lap over the injury in all directions. (See Limitations.) (Hold shears at an angle
to produce a beveled edee (feather) on the patch.) Round cornen of patch. (Dull side or gum contact face of
repair patch should be the largest surface after beveling.)
2. Wash one square foot of cell wall surrounding the injury. and the repair patch contact side with a
clean cloth soaked with Methylethylketone solvent.
3. Abrade cell wall surface about the injury and on the contact side of patch with fine emery cloth to
remove the shine.
4. Repeat Methylethylketone washings two more times, for a total of three washings for each surface.
5. Tape a 8" x 8" piece of cellophane inside the cell over the injury.
6. When all the above preparatory work has been done and the cell has been positioned for patch
application on the repair table, mix the 8 K 2 7 cement (320 gms) with the cross-linker 80C28 (81cc), and stir
mixture thoroughly, for five minutes.
.-
-NOTE Cement r m s t be at a minimum oj 70° F w o r e mixing. Keep w a y
jrom water and excessive heat.
7. Brush one even coat of mixed repair cement on the cell wallaround the injury and on the contact side
of the repair patch. Allow to dry for fifteen minutes.
8. Repeat a second mixing of repair cement and brush a second coat.
-
CAUTION
-
1
D o not use the fist can 01mixcd #mmt jor this coat.
I
I
9. Allow cement to dry approximately five minutes, and then center patch over injury. Lay the repair
patch by rolling it down on surface from center to edge without trapping air. Hold the unrolled portion of the
repair patch off the cemented surface until roller contact insures an air-free union. At this time, the repair
patch may be moved by hand on the wet surface to improve lap. Do not lift the repair patch. slide it.
Make sure the cellophane inside the el o v a the injury remahs in
place, as my cemnt will stick the cell walls togetha without the
cellophane as a separator.
10. Cover one smooth surface each of two aluminum plates (plates must be larger than patch), with
fabric-backed airfoam, fabric side out. Tape airfoam in place. Foam must cover edges of the plate for
protection. Use a cellophane separator to prevent the cement .from sticking in the wrong place.
I I. Fold the cell adjacent to the patch and place prepared plates one over repair patch and one on
opposite side.
28-12-12
Page 28-12
Revised: August 11,1983
I
I
I
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
12. Center a repair iron 2F1-3-25721-1 on plate over the repair patch. Secure the assembly with a "C"
clamp. Tighten by hand. Check cement flow to determine pressure.
- CAUTION -
Make nrre that the cell jbld & not chmped betwetn pktes. This
wmld cause a hardpermanent c-c
A k o make w e that thepatch
does not m v e w k n chmp is tightened
13. Connect the repair iron into 1 10-volt current and cure the repair for two hours. After two hours cure.
unplug repair iron and allow it to cool to touch. Then remove the "C" clamp. Wet the cellophane t o remove it
from the repair.
14. The inside patch is applied the same as the above procedure except for side of the repair patch (see
Limitations), after the outside patch has been cured.
- CA UTION -
Success of appiymg both an outside and inshie repair patch
simultmmusly is doub@l and not recommended
REPAIR PATCH (AIR CURE METHOD).
Follow the procedure for the heat cure method, except omit repair iron, and cure each patch per air
limitations (minimum 72 hours). undisturbed at 7S°F.
ACCESSORY REPLACEMENT.
1. Obtain a cured repair accessory from the cell manufacturer.
2. Mark location of old accessory and preserve markings for guide lines to locate the new part.
3. Remove the old accessory by gradually loosening an edge with a blunt probe-like instrument.
4. When a loose edge is created. grasp the accessory by the loose edge with pliers and gently peel the
accessory off the cell wall. Be careful not to pull the cell lap open while peeling accessory off. Pull from the
blind side of a cell lap toward the exposed edge.
5. Buff the cell surface under the accessory with emery cloth to smooth roughness and prepare for
cement.
-NOTE -
Removal of the old acnssory wiUpab46b ltave an uneven cavity
and sudace.
6. Prepare the replacement accessory by buffing and washing the contact surface. Also wash the cell
surface (see repair patch).
7. Apply mixed 80C27 repair cement to both surfaces being sure to level the cavity left by the removal of
the old accessory.
8. Roll the new accessory into place as with a repair patchand place suitable padded plates in position to
insure adequate pressure when clamped. Use a cellophane separator to prevent the cement from sticking in the
wrong place.
9. Cure with either cure method.
28- 12-14
Page 28-13
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
DEFECT REPAIRS OF FUEL CELL.
-
I. Blisters: Remove loose material by trimming. Apply an outside and inside repair patch.
2. Holes. Punctures. Cuts. Tears and Deep Abraded Areas: Trim away any ragged material and apply
an outside and inside repair patch.
3. Loose Seams: Buff loose edges and contact surfaces with emery cloth. Wash three times with
Methylethylketone. Apply 80C27 mixed cement in two coats a s with a repair patch. Clamp and cure. Either
method may be used. (See repair patch.) Loose seams may be trimmed if a minimum lap remains.
4. Loose Fitting Flange Inside: Buff the edge of the flange and the contact surface under the flange.
Apply 80C27 mixed repair cement. cellophane. padded plates and clamp. Follow procedure as outlined for
repair patch.
5. Looseness Against Metal: Prepare metal as per metal fitting sealing surfaces. Apply 80C27 mixed
cement and cure.
-
-
TESTING FUEL CELLS.
Either of the following procedures may be used to detect leaks in the bladder cells:
1. Soap Suds Test:
A. Attach test plates to all fittings.
B. Inflate the cell with air to a pressure of 114 psi MAXIMUM.
C. Apply a soap and water solution to all repaired areas suspected of leakage. Bubbles will appear
at any point where leakage occurs.
D. After testing. remove all plates and wipe soap residue from the exterior of the cell.
2. Chemical Test:
A . Attach test plates to all fitting openings except one.
B. Make up a Phenolphthalein solution as follows: Add 40 grams Phenolphthalein cqstals in I 2
gallon of Ethyl Alcohol. mix: then add 1 !2 gallon of water.
C. Pour ammonia on an absorbent cloth in the ratio of 3 ml per cubic foot of cell capacity. Place a
saturated cloth inside the cell and install the remaining test plate.
D. lnflate the cell with air to a pressure of 114 psi maximum. cap and maintain pressure for fifteen
minutes.
E. Soak a large white cloth in the Phenolphthalein solution. wring it out thoroughly. and spread it
smoothly on the outer surface of the cell. Press the cloth down to insure detection of minute leaks.
F. Check the cloth for red spots which will indicate a leak. Mark any leaks found and move the
cloth to a new location. Repeat this procedure until the entire exterior surface of the cell has been covered. If
red spots appear on the cloth. they may be removed by resoaking the cloth in the solution.
G. The solution and test cloth are satisfactory only as long as they remain clean. Indicator solution
that is not in immediate use should be stored in a closed rust proof container to prevent evaporation and
deterioration.
After the test. remove all plates and test equipment. Allow the cell t o air out.
In conducting either test outlined above. the cell need not be confined by a cage or jig. providing the 1 4
psi pressure is not exceeded.
The chemical red is the more sensitive and przfened test.
28-12-16
Page 28-14
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
INSPECTION OF FUEL SYSTEM.
Fill tanks with fuel. Inspect tanks and fuel line connections for leaks. If fuel tanks leak, follow instructions
given in Inspection and Repair of Fuel Tanks. lf fuel line connections leak, tighten clamps or replace hose
connections after first draining tanks.
LOCKING FUEL CAP.
DISASSEMBLY OF LOCKING FUEL CAP.
1.
2.
pawl.
3.
4.
Remove the two screws from the top of the fuel cap. (Refer to Figure 28-4.)
Remove the screw and lockwasher which secures the pawl to the bottom of the key lock. Remove the
Remove the nut which secures the key lock to the cover.
Slide the lock, gaskets and spring over the back of the key lock.
5. The key lock may be removed by pushing the key lock through the cover. Ensure that the "O"ring is
not lost.
ASSEMBLY OF LOCKING FUEL CAP.
1. Insert the key lock through the cover, making sure that the "0"ring gasket is installed under the head
of the key lock.
2. Slide the spring. gaskets and lock over the back of the key lock.
3. Reinstall the nut which secures the key lock to the cover.
4. Attach the pawl to the back of the lock assembly with the screw and lockwasher.
5. Apply a thin coating of PR-1422, Class A-2 sealant t o the shank and thread of the two screws, then
reinstall the screws and lockwashers on top of the fuel cap.
T H l S SPACE INTENTIONALLY LEFT BLANK
28- 14-02
Page 28-1 5
Revised: August 23. 1982
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
1
KEY LOCK
GASK€l
SPRING
-
LOCK
GASKET
1
PAWL ASSEMBLY
LOCK
k
Figure 284. Installation of Locking Fuel Cap
FUEL SELECTOR VALVE OPERATION.
When the fuel selector handle is not in a positive selector detent position. more than one fuel port will be
open at the same time. I t should be ascertained that the fuel selector is positioned in a detent. which can be
easily felt when moving the handle through its various positions.
28-21-00
Page 28-16
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
REMOVAL OF FVEL SELECTOR VALVE AND FILTER.
I . Drain fuel from tanks. (Refer to Draining Fuel System. Chapter 12.)
2. Remove center seats. seat belt attachments and floor panel just aft of the main spar by removing the
floor attachment screws. Lift the panel and remove.
3. Remove plate from bottom of the fuselage which covers fuel selector.
4. Disconnect the fuel lines and selector linkage from valve assembly.
5. Remove the four mounting screws which hold the fuel selector in place and remove the selector
assembly.
Am0
I
I
1 FILTER
2 SPRING
NYLON FILTER ASSEMBLY
3 RETAINER WASHER
4 BOWL
Figure 28-5. Fuel Filter
2B12
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAISTENANCE MANUAL
CLEAKISG FILTER ASSE31BLY.
1.
I filter
R e m o \ e the access panel t o the filter bou,l o n the bottom of the fuselage.
2. Remo\ e fuel strainer bow 1.
3. R e m o l e filter disc assembly from center stem by compressing filter retainer spring and remo\ ing
retainer basher. (Refer t o Figure 2 8 - 5 . )
Inspect bowl gasket and replace I! necessar!..
5 . Filter discs may be cleaned as follows:
A . Plug open ends of filler disc center with stoppers t o pre\.ent dirt from entering.
B. N'ash metallic filter disc in acetone. gasoline. carbon tetrachloride. trichorethylene (permachor
o r Bendix cleaner. Wash n!.lon filter disc with soap a n d water.
4.
Do not use acetone, methylethylketone, etc., to clean nylon filter
discs.
C.
Remole stubborn deposits from filter disc with a soft bristle brush.
-
,
D. Rinse all traces of s o a p solution. Drain o r blow dr\. and rem0L.e stoppers
6 . Replace the iilter disc if damage I S e\ident.
7 . Reinstall filter disc assembl!. and strainer b o b ] .
I S S T A L L A T I O S OF F L E L SELECTOR \'ALVE A N D FILTER.
-
I.
Position the \.al\e inside the airplane just aft of the main spar.
2. Secure the 1-al\e with machine screws. washers and self-locking nuts.
3. Connect the fuel lines.
3.
Connect fuel selector \.alle linkage t o insure that selector handle engages the left indent position u hen
i t is against the safe!! stop on the console co\-er.
5 . Fill the fuel tanks and check all connections for leaks.
Instal! the rear seat and fuel drain placard co\er.
7 . lnstall the access plate to the bottom of the fuselage with attaching screws.
6.
-- NOTE
-
H'hen installing the fuel selector valve, it is recommended the
complete fuel system and tanks be drained and flushed to ascertain
no contamination is present. (Refer to Cleaning Fuel System.)
C L E A N I S G F L E L SYSTEM.
1. Remo\.e all fuel from tanks. The fuel should be drained through a chamois o r other straining
equipment t o inspect for the presence of foreign matter.
2. Each tank should be flushed by opening the tank drain and adding two-three gallons of clean fuel.
N'hile the fuel is draining. the aircraft wing should be raised and lowered t o allou the fuel t o rinse an!
contamination still remaining in the tank out the drain.
28-22-OC)
Page 28-18
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAISTENANCE MANUAL
3. After the \ a l \ e is installed and the a ~ r c r a f trefueled. the fuel inlet line t o the iniector should be
disconnected a n d \+,th boost pump on. l ~ n e sshould be flushed while selector is m o \ e d from one tank to
another.
4. J t a k e proper logbook entr!.
ELECTRIC Ft'EL P t . \ l P .
RE31O\'AL A N D INSTALLATION O F ELECTRIC FL'EL P r M P .
I. Turn the fuel selector t o the off position.
2. Rem0L.e the floor panel that is located directly aft of the main spar by removing the center seat.. >eat
belt attachments a n d the screws that secure the panel. Lift the panel and remo\-e it from the a ~ r p l a n c .
3. Disconnect the electrical lead from the p u m p .
4. Disconnect the inlet and outlet lines from the p u m p .
5 . O n PA-32-301T disconnect \.ent tube from bottom of the pump.
6 . R e m o \ e the pump b! remo\ ing the p u m p attachment hardware.
7 . Reinstall the fuel p u m p in re\erse of remo\al.
THIS SPACE INTETSTIONALLI' LEFT BLANK
28-23-00
Page 28-19
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
F U E L QL.ASTIT1' S E N D E R L:NIT.
- NOTE Inboard and outboard fuel tanks in each wing are interconnected
and have a total capacity oj53.5 gallons. Fuel quantity sender units
mounted in each fuel tank transmit electrically the cumulative
quantity ofjuel in each set of tanks, tofuelquantity gauges mounted
in the instrument panel.
F U E L QL'ANTITY SENDERICAC'GE CHECK (INSTALLED).
p r \ ~ n i ~ r::
Fuel quantity sender units and fuel quantity gauges can bechecked while mounied in the airplane b!- uslnf
the follouing procedure:
I . Put the fuel selector le\.ers in the "OFF"position. Completelydrain fuel tanks that relate t o the fuel
quantity senders and gauge t o be checked. (Refer t o Draining Fuel System. Chapter 12.)
2. Le\.el a ~ r p l a n elaterall! (refer t o Leveling. Chapter 8) and position the aircraft with a 1 degree nose up
attitude.
- NOTE The electrical system should supply 12 to 1Cvolts to the gauge.
3. N'ith the master switch in the " O F F position. thegauge needle should becentered o n the white dot t o
the left of the "0"r a d ~ a mark.
l
with a m a s i m u m deviation o f 1 , 4 n e e d l e width. If not within t h ~ tolerance.
s
the
gauge should be replaced.
4. N'ith the master switch in the "OX" position and n o fuel in the tanks. the gauge needle should be
centered on the white dot t o the left of the "0"radial mark with a maximum deviation of 1 4 needle width. I f
not withln t h ~ stolerance. the gauge should be replaced.
5. Place 2 . 5 gallons of fuel in the wing fuel tank that relates t o the gauge and sender unit beingchecked.
6. With 12 to 14-volts DC supplied t o the electrical system and the master switch in the "OX" position.
the needle should be centered o n the "0" radial mark; plus 0.minus 1 fi needle. width.
7. If the needle does not read within t h e above tolerance. remove the sender wire from the rear of the
gauge and check the resistance t o ground through the sender circuit. If the resistance is not within 5 2 1 o h m s .
replace the inboard sender. Then. recheck a s specified above.
8. Add fuel to the tanks in accordance with the information given in Chart 2802 until tanks are full.
Observe the gauge reading at each 10 gallon increment.
9. With the tanks full and master switch "Oh:,"
the needle should be centered on the "F'radial mark
within 2 1 needle width. If not within this tolerance. adjust the electrical adjustment (refer t o Figure 28-6)just
sufficiently t o bring it within tolerance; d o not center the needle.
28-41-01
Page 28-20
Revised: August 1 1 . 1983
~
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
b
EMPTY DOT
h a \ \ \
I I
ELECTRICAL
ADJUSTMENT
ACCESS HOLE
Figure 28-6. Fuel Gauge
C H A R T 2803. S E N D E R F U E L Q U A N T I T Y G A U G E T O L E R A K C E S
TOTAL FUEL I S
GAUGE READING
TOLERANCE
RESISTANCE
T A N K S (U.S. G A L L O N S ) (U.S. G A L L O N S ) ( K E E D L E W I D T H S ) ( O H M S . BOTH SEIVDERS)
-- END
-
28-4 1-0 1
Page 28-21
Revised: August 11. 1983
CHAPTER
LANDING GEAR
PIPER AIRCRAFT
PA-32-301 1301T
MAIKTEIVANCE MATVLAL
-
CHAPTER 32 LANDISG GEAR
TABLE O F CONTENTS/EFFECTIVITI'
SLBJECT
GRID
10.
EFFECTI\'ITI'
GEYER.AL
Description
Troubleshooting
31.41V GE.4R
hlain Gear Oleo
Disassembl! of Main Gear Oleo
Cleaning. lnspection and Repair of Main Gear Oleo
.4srembl! of Main Gear Oleo
A1 ain Gear .Assembl!
R e m o t a l of Main Landing Gear Assembl!
Cleaning. lnspection a n d Repair of Main
Landing G e a r .Assembly
Installation of Main Landing Gear
\OSE G E A R '
\ o s e Gear Oleo
Disassembl! of Vose Gear Oleo
Cleaning. lnspection and Repair of S o s e Gear Oleo
S o s e Gear Oil Orifice Retainer Ring Installation
Assemhl! of S o s e G e a r Oleo
S o s e Gear Assembl!
R e m m a l of S o s e Landing Gear and Engine Mount
Cleaning. lnspection and Repair of Nose Landing
Gear and Engine M o u n t
Installation of Nose Landing Gear and Engine Mount
Alignment of Nose Gear
U'HEELS A S D BRAKES
Main U'heel
R e m o \ a l and Disassembly of Main \'heel
lnspection of Main Wheel Assembl!.
Assembl! a n d lnstallation of Main Wheel
Kose U'heel
R e m o \ a l and Disassembly of h o s e Wheel
l n s p e c t ~ o nof Nose \'heel Assembly
Assembl! a n d Installation of h o s e Wheel
Assem bl!.
-
32 Cont./Effec.
Page I
Revised: August 1 1 . 1983
-
PIPER A I R C R A F T
PA-32-301 /301T
hlAlNTENANCE MANUAL
-
CHAPTER 32 LANDISC GEAR (cont)
TABLE OF CONTENTS/EFFECTIVITY
CH 4PTER
SECTIOS
SL'BJECT
SUBJECT
CiRID
SO.
EFFECTI\'ITI'
\!'HEELS A1'D B R A K E S ( c o n 0
Brakes
Brake .4diustment a n d Lining Tolerance
R e m o ~ a al n d Disassembly of Brake Assembly
Cleaning. Inspection a n d Repair of Brake Assembl!
Assrmbl! a n d Installat ion of Brake Assembl!.
Brake Master C!.linder
R e m o \ a l of Brake Master Cylinder ( H a n d Brake)
Disassembl! of Brake hlaster Cylinder
Cleaning. Inspection a n d Repair of Brake
Alaster C! linder
.Assembl! of Brake Master Cylinder
Installation of Brake Master Cylinder ( H a n d Brake)
Brahe C!linder ( T o e Brake)
R e m o \ a l of Brake C!.linder ( T o e Brake)
D~sassembl! of Brake C! linder
Cleaning. Inspection a n d Repair of Brake C!.linder
Assembl!. of Brake Cylinder
Installation of Brake Cylinder
Brahe Bleeding Procedure ( G r a \ it! )
Brake B l e e d ~ n gProcedure (Pressure)
Brake S!stem Leak Check
B l e e d ~ n pOf Brakes After A ['nit Is Changed
\!'HEEL F A I R I S G S
M a ~ nN'heel Landing G e a r Fairing Remo\.al a n d
Installation
S o s e G e a r Fairing Remo\-al a n d Instaliation
-
Revised: August 1 1.'.I 983
PIPER AIRCRAFT
PA-32-3011301T
MAINTEIVANCE MANUAL
a
GENERAL.
In this chapter are instructions for the remo\,al. disassembl!. inspection. overhaul and installation of the
landing gear and brake s!.stem components. The alignment of the nose gear. and the repair and senice of the
brake system.
DESCRIPTIOS.
I
a
The landing gear is a fixed tricycle t!.pe. fitted with 6:00 x 6 main gear wheels and 5:00 s 5 I6:OC) \ 6
optional) nose gear wheels. The landing gear struts are of the air-oil type. The nore gear. steerable through a
wide arc. enables a short turning radius in each direction. T o aid in nose wheel and rudder centering and to
p r o ~ i d erudder trim there is a spring de\.ice attached to the rudder pedal torque tube assembl!. A s h ~ m m !
dampener is also incorporated in the nose wheel steering mechanism.
The two main w.heeIs are equipped w.ith a single disc hydraulic brake assembl! which is actuated b! a hand
le\.er connected to a cylinder located below and behind the center of the instrument panel. or b! indilidual
c!.linders attached to each rudder pedal. The hand lever also doubles as a parking brake and ma! be operated
b! pulling back on the handle and depressing the knob attached to the top of the handle. To relea3e the p a r h ~ n g
brake. pull back on the brake handle t o disengage the catch mechanism: then allow the handlc to s\\lng
forward. A brake fluid reser\olr is installed on the left forward face of the engine fireuall.
Troubles peculiar to the landing gear are listed in Chart 3201. along with their probable cau>e\ and
suggested remedies. U'hen troubleshooting the landing gear system. it ma! be found that ~t is necei5ar) I O place
theairplane on jacks. I f so. refer to Chapter 7
32-02-00
Page 32-01
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
C H A R T 3201. TROL'BLESHOOTING (LANDING G E A R )
Trouble
Xose landing gear shimmies
during fast tasi. take-off.
o r landing.
I
I
Excessi\.e or une\.en n e a r
on nose tire.
S o s e gear fails t o steer
properly.
Cause
2
I
Remed!-
Internal wear in shimmy
dampener.
Replace shimmy dampener.
Shimmy dampener o r
bracket loose at mounting.
Replace necessar! parts and
bolts.
Tire out of balance.
Check balance and replace
tire if necessar!.
Worn o r loose wheel bear~ngs.
Replace and o r adjust u heel
bearings.
Worn torque link bolts
and o r bushings.
Replace bolts and or
bushings.
Improper nose wheel
fairing.
Replace uith proper fairing.
Incorrect operating
pressure.
Inflate tire to correct
pressure.
Wear resulting from
shimm!.
Refer to proceeding< for
correction.
Oleo cylinder binding in
strut housing.
Lubricate strut housing.
(Refer to Lubrication
Chart. )
I
I
C!.linder and o r strut housing bushings damaged
i
One brake dragging.
Determine cause and correct.
Steering bellcrank loose o n
attachment plate.
Readjust and tighten.
Steering bellcrank bearing
and : o r bolt worn.
Replace bearing and or
bolt.
Shimmy dampener galling
o r binding.
Replace.
i
I
I
32-02-00
Page 32-02
Revised: August i 1. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MAIVL'AL
Trouble
hlain landlng gear shimmies
during fast t a l i . ta ke-off.
o r landing.
Excessi\e or uneten u.ear
on main tires.
Strut bottoms on normal
landing or taxiing on rough
ground
Cause
I
I
Remed!
Tire out of balance.
Check balance and replace
tire if necessar!.
Worn o r loose n.heel bearIngs.
Replace and o r adjust
bearings.
Worn torque link bolts and
o r bushings.
Replace bolts and or bushings.
Incorrect operating pressure.
Inflate tire to correct
pressure.
\'heel out of alignment (toe
in o r o u t ) .
Check uheel alignment.
Insufficient air and o r
fluid in strur.
S e n ice strur with air and
o r fluid.
\\
heel
32-02-00
Page 32-03
Revised: August 1 1 . 1983
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
MAlN GEAR.
I
MAlN GEAR OLEO.
DISASSEMBLI' O F M A l N GEAR OLEO. (Refer t o Figure 32-1.)
T h e main pear asle and piston tube assembly may be removed from the cylinder housing u i t h the gear
remoied from or installed on the airplane. O n some airplanes the metering components of the gear that are
located in the top of the housing ma!- be remo\.ed. but only with the gear remo\.ed from the airplane. (Refer to
Removal of Gear.)
I . Place the airplane on jacks. (Refer t o Chapter 7.)
2 . Place a drip pan under the main gear t o catch spillage.
3 . The gear asle and piston tube assembl!. may be removed by the following procedure:
A. Remo\e the air from the oleo chamber by depressing the air val\e core pin found in the
inspection hole on top of the wing. After the pressure in the oleo chamber has diminished. remo\e the \ a l \ e
core pin. attach a small hose t o the air val\.e. and drain the fluid by slowly compressing the piston tube. I f it i.
desirable to extract more fluid from the chamber. remove the filler plug. insert a siphon hose and drain fluid
from the upper area o f the housing.
B. Disconnect the flesible brake line at the elbow on the brake assembl!.
C . Disconnect the torque link assembl!. by removing any one of the three cotter pins. nuts. u asher3
and bolts. S o t e arrangement of the components for reinstallation. Carefully slide the piston tube from the
c!.linder housing.
D. T h e scraper ring located inside the lower end of the cylinder housing may be remmed b! flrst
rernoiing the retainer ring. spacer ring and then the scraper ring.
E. T h e O-ring seal located just before the scraper ring may be remo\.ed by using a cur\ ed ire or
spoon shaped tool and inserting i t under the ring.
4. The c\linder head and the orifice assembly. may be removed by the following procedure:
.4. Cut safet). wire and remo\e the bolts that secure the cylinder head in the top of the houiing.
R e m o i e the ;~ssembl!. from the housing.
B. Lubricate and install a n O-ring on the cylinder head assembly.
C . T h e orifice assembl!. may be removed from within the housing by rotating it countercloch\\lce
out of the housing u ith the use of a .50 s ,125 stud t!,pe spanner wrench. (Refer t o Chapter 95.) D o not remo\ e
orifice unless it necessitates replacement.
CLEAKINC. ITSPECTION Ah'D REPAIR O F MAIN GEAR OLEO.
I. Clean all parts u i t h a suitable dry type cleaning solvent.
2. Inspect the landing gear oleo components for the following:
A. Bearing surfaces of housing for excess wear. corrosion. scratches and overall damage.
B. Retaining ring for cracks. burrs. etc.
C . Cylinder tube for corrosion. scratches. nicks. excessive wear and misalignment.
D. Air \.alve for operation and general condition.
E. Orifice plate for hole restriction.
3. Repair of the oleo is limited t o smoothing out minor scratches. nicks and dents. and replacement of
parts.
32-1 1-02
Page 32-04
Revised: August il 1983
.
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
1
2
3
4
5
6
7
8
9
10
11
12
CAP. VALVE
PLUG FILLER
O-RING
HEAD CYLINDER
O-RING
DELETED
O-RING
ORIFICE ASSEMBLY
STRUT HOUSING
WASHER
NUT
WASHER
13
14
15
16
17
18
19
20
21
22
23
TORQUE LINKS
O-RING OR QUAD RING
RING. SCRAPER
RING. SPACER
RING RETAINER
TUBE. PISTON
AXLE STUB
SPACER
SPACER
NUT WHEEL RETAINER
PIN. CLEVIS
Figure 32-1. Main Gear Oleo Strut Assembly
32-1 1-02
Page 32-05
Revised: August 1 1, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANC'AL
ASSEMBLY O F MAIN GEAR OLEO. (Refer t o Figure 32-1.)
I. Install the orifice assembl!. if remo\,ed. by the folloiing procedure:
.4. Lubricate with hydraulic fluid (MIL-H-5606) and install an O-ring in the annular slot in the
metering orif~ce.
B. Insert the orifice through the opening in the t o p of thegear housing and turn it into the threaded
hole web. Tighten the orifice with the use of a stud type spanner wrench.
C. Lubricate and install a n O-ring o r apply a thin layer of Permatex Forma-Gasket S o . 6 S e a l a n ~ .
directly underneath the flange of the cvlinder head.
D. Insert the tube of the metering assembly through the opening in the top of the housing and into
the orifice. Use caution not t o cut o r dislodge the O-ring slot in the orifice.
E. Secure the metering tube assembly with bolts and safety with MS20995-C32 wire.
2. Assemble the components of the piston tube on the tube by placing. in order. the retainer ring. spacer
ring and scraper ring. Insert an O-ring into the annular slot in the bottom of the housing.
insert it into the housing being careful not t o damage or
3. Lubricate the w.aII of the piston and ~arefull!~
dislocate the O-ring in the housing.
4 . Ascertain that the bushings are installed in the upper and lowertorquelinksand then install links. .r41
cable end of each link. install with the use of brake line bracket. bearing washers. bolt. washer. nut and cotter
pin. Do not o \ e r tighten causing binding o r damage to the link. At the connection point of the upper and lower
links. attach w.ith the use of brake line brackets. spacer washers. grease bolt. washers. nut and cotter pin?.
Install washers (AK960-816L) under the head of the bolt t o allow a firm sliding fit between the t\xo I ~ n h s .
5. Slide the scraper and spacer rings into place and secure with the retainer ring in the annular slot in the
bottom of the housing.
6. Install the h!.draulic brake line.
7 . I f remo\.ed. install the landing gear. (Refer t o Installation of Main Landing Gear.)
8 . Ser\ice0the oleo strut as gi\en in Oleo Struts. Chapter 12.
9. Actuate the gear seieral times b!. hand to be certain it operates freel!.
Links should be loose enough to allow free action o j the gear, bur
also resist side play. For lubrication o j links, refer to Chapter 12.
10. Rem0i.e the drip pan and slowly lower the airplane from the jacks.
1 1 . If necessar). bleed brakes. (Refer to Bleeding Brakes.)
I
M A l S GEAR ASSEMBLIP.
REMOVAL O F MAIK GEAR ASSEMBLY. (Refer t o Figure 32-2.)
I. Place the airplane on jacks. (Refer t o Chapter 7.)
2. Place a drip pan under the main gear t o catch spillage.
3. If desired. rem0i.e the air from the oleo chamber by depressing the air \.al\.e core pin found in the
inspection hole on top of the wing. After the pressure in the oleo chamber has diminished. remo\e the \.al\e
core pin and attach a small hose t o the air valve and drain the fluid by slowly cornpressingthe piston tube. If i t
is desirable t o extract more fluid from the chamber. remove the filler plug. insert the siphon hose and drain
fluid from the upper area of the housing.
4. Rem0L.e the fairing from around the cylinder housing.
32-1 2-0 1
Page 32-06
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
31.1ISTENASCE > I A S l ' . 1 L
S CR E Lm'
AIR \ ALVE CAP
BOLT
AIR VALVE
CYLI~DER
BOLT
BRAKE L l h E HOSE
BOLT WASHER NUT 8 COTfER Plh
OLEO ASSEMBLY
TORQUE LlNK ASSEMBLY
TORQUE LlNK ASSEMBLY
STUB AXLE
Figure 3 2 - 2 . Main G e a r Installation
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MAKUAL
5 . L'nhook the hydraulic brake line inside the wing assembl!.. This is accessible through the access plate.
C a p the line b! use of'a threaded cap o r wrapping with plastic.
6 . Remo\e the top four bolts by holding them with a slotted screwdrit.er and turning the nut u.ith the
appropriate t\rench. Remote the remaining six by use of a wrench. Carefully remove thc gear assembl! from
the uing.
( C L E A S I S C . ISSPECTIOS A N D REPAIR O F M A l N GEAR ASSEMBLY.
I . Clean all p a n s with a suitable dry type cleaning solt.ent.
2. Inspect the gear components for excessive wear. corrosion and damage. Check the cylinder housing
and torque links for cracks. nicks and misalignment.
3. Repair of the landing gear is limited t o reconditioning of parts. replacement of parts. s m o o t h ~ n go u ~
minor nicks and scratches and repainting areas where paint has chipped o r peeled.
I
INSTALLATION O F MAIN GEAR ASSEMBLY. (Refer to Figure 32-21
I.
T h e main landing gear assembl), may be installed on the wing by the follou.ing procedure:
.4. Position the gear up in the a.ing through the access opening and secure N ith bolt$. \I a,herk and
nut<.
B. Reconnect the brake line at the point of disconnection.
2. Sert ice the oleo strut. (Refer t o Chapter 12.)
3 . Ser\ ice the brake system. (Refer to Chapter 12.)
4 . Install the access plate t o the bottom of the wing and the oleo housing fairing to the gear.
5 . S l ~ d ethe drip pan from under the gear and remove the airplane from the lacks.
h O S E GEAR.
1 S O S E GEAR OLEO.
DISASSEMBLY O F NOSE GEAR OLEO. (Refer to Figure 32-3.)
T h e nose gear oleo strut assembly ma!. be removed and disassembled from the strut housing u ith the gear
remot-ed from or installed on the airplane.
I. R e m o t e the louer engine cou~ling.(Refer to Chapter 7 1 .)
2. Place airplane o n jacks. (Refer t o Chapter 7.)
3. Place a drip pan under the nose gear t o catch spillage.
4. T o remove air from the strut. depress the air valve core pin found at the top of the strut assemhl!.
After t h e pressure in the strut chamber has diminished. remove the \alve core pin. and attach a small hose to
the air talt-e. and drain the fluid by slowly compressing the piston tube. If it is desirable t o extract more fluid
from the strut chamber. remoi8ethe filler plug. insert the siphon hose and drain fluid from the upper area of the
housing.
32-21-01
Page 32-08
Revised: August 11. 1983
-
PIPER A I R C R A F T
PA-32-30113011
MAINTENANCE MANUAL
I
1768
1 . NUT. RETAINER
2. WASHER
BEARING TOP
STRUT HOUSING
BEARING. BOlTOM
CAP. VALVE
PLUG. FILLER
TUBE. METERING
9. CYLINDER
10. RING. RETAINER
11. SNAP RING
12. BEARING
13. O-RING. PACKING
14. O-RING OR QUAD-RING
15. WASHER. BACK-UP
16. WIPER STRIP
17. TUBE. PISTON
1 8 . O-RING
19. PLUG. PISTON TUBE
20. PLUG. ORIFICE
3.
4.
5.
6.
7.
8.
Figure 32-3. Nose Gear Oleo Strut Assembl!
32-21-01
Page 32-09
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
5. To remo\e the strut assembl! from the strut housing. cut the safety wire at the top of the housing that
secures the steering horn attaching bolt to the tube retainer nut. Then remo\,e the steering horn attaching bolt<
thus relieling the steering horn from the top of the strut housing.
6 . Loosen the strut assembly retainer nut that secures the strut assembly.in the strut housing. At the
same time. slide the strut assembly out through the bottom of the strut housing. Remove the nut and washer
from the top o i the strut housing after the assembl! is removed.
The strut assemb!v may fit tight inside o j the housing. It may be
necessary to tap the top o j the fork with a plastic mallet.
7. If desired. remo\,e the top and bottom bearing from the strut housing. The bearings are compressed
slightly into place. and light tapping may be needed t o free them.
8. To remole the piston tube and fork assembl! from the cylinder. proceed as follous:
A. Separate the upper and lower torque links by removing the connecting nut. washer and bolt.
B. Compress the piston tube and fork assembly slightly and remove the retainer ring from the
annular slot in the bottom of the cylinder tube. Then remove piston tube and fork assembl! b!. sliding out from
the bottom of the cylinder tube.
9. T o remo\.e the bearing assembl!. from the piston tube. release the snap ring from the top of the p1.tor-i
tube and slide b e a r ~ n assembl!
i
off the end.
A . If desired. carefully remo\.e the wiper strip. back-up washer and quad ring or O-ring irom the
inside of the bearing slee\e. and also the O-ring gasket from the outside of the bearing slee\e.
10. T o remo\-e the piston tube plug with O-ring located in the louer end of the tube. the follo\\~n_e
procedure ma!. be used:
A . Remo\e the nose wheel from the fork. (Refer t o Removal and Disassembl! of Nose \{'heel.)
B. Loosen and remo\e the bolt. washer and nut that extends through the piston tube and block
assembl! .
C. Push the plug through the top of the piston tube by use of a rod inserted through the bottom of
the tube.
C L E A S I S G . INSPECTION A N D REPAIR OF NOSE GEAR OLEO.
I . Clean all parts with a suitable dr!, type cleaning solvent.
2. Inspect the landing pear oleo assembly component for the following:
A.
C!.linder tube assembl!. for corrosion. scratches. nicks and excessi\-e wear.
B. Lock rings for cracks. burrs. wear.
C. Fork assembl! for corrosion. scratches. nicks. and mLalignment.
I
I
I
D. Link assembl!. for elongated holes. cracks. corrosion. scratches. nicks and straightness.
E . General condition of air val\,e.
3. Repair of the oleo is limited to smoothing out minor scratches. nicks and dents and replacement of
parts.
32-21-02
Page 32-10
Revised: August il. 1983
•
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
a
NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATION. (Refer t o Figures 32-3 and 32-3.)
-
1 . H'ith the piston tube and fork remo\,ed from the cylinder. ascertain that all traces of the old retainer
ring are removed from the metering tube.
2. A tool can be fabricated t o simplify the installation of the new retainer ring. (Refer to Chapter 91 . I
3. H'ith the use of the fabricated tool. position the new retainer ring on the end of the tool with the
locating stud.
4. insen the tool into the cylinder. with the centering stud positioned into the hole in the base o f the
metering tube.
5. Hold the tool tightly against the metering tube and slide the sleeve of the tool towards the metering
tube. This will mo\e the new retainer ring over the end of the metering tube and position itself into the groo\e
of the metering tube.
ASSEMBLY OF NOSE GEAR OLEO. (Refer t o Figure 32-3.)
a
-
I . Ascertain that all parts are cleaned and inspected.
2. T o install the piston tube plug. proceed as follows:
A . Lubricate the tube plug and O-ring with hydraulic fluid (MIL-H-5606) and install the O-ring on
the plug.
B . Lubricate the inside wall of the piston tube. and insert the plug into the t o p of the tube. pushing it
t o the fork end.
C . Align the bolt holes of the fork. tube and plug: install the bolt. washer and nut.
3. Carefull! install in the bearing sleeve the quad ring. back-up washer and the wiper strip. Slide the
O-ring in place on the outside of the slee\.e.
4. Lubricate the bearing assembly and carefully install it on the piston tube.
5 . Position the snap ring o n the upper end of the piston tube.
6. Insert the piston tube with bearing assembly in the cylinder tube. Secure it with the retainer ring in the
annular slot at the bottom of the tube.
7. Connect the torque links on the tube and fork securing them with a bolt. washer and nut. Tighten the
nuts only tight enough t o retard side play. but still allowing the links t o rotate freely.
8. Ascertain that the upper and lower bearings are installed in the strut housing. Bearings are a press fit
with the grooves in the inner and outer races in the up position.
9. Position washer and strut assembly retainer nut on t o p of the strut housing. Insert the strut assembl!
u p through the u.asher until it contacts the nut. Tighten the nut t o a snug fit.
10. T o install the steering horn assembly. insen the hex bolt through the side of the horn and top of the
strut assembl!. When it protrudes through the other side of the steering horn. install the washer and nut.
I I . Install the steering horn attaching bolt through the t o p of the horn into the strut assembl!,. D o not
tighten bolt at this time. If a space appears between the steering horn plate and the top of the strut assembly. it
will then be necessary t o install spacer washer(s). (AN960-416L). between the horn and strut. Then tighten the
bolt and safety the bolt to the strut assembly retainer nut with MS20995C40 wire.
12. Compress and extend the strut several times t o ascertain that the strut will operate freely. The weight
of the gear wheel and fork should allow the strut t o extend.
13. S e n k e the oleo strut with fluid and air. (Refer t o Chapter 12.)
14. Check the gear for alignment. (Refer t o Alignment of Nose Landing Gear.)
32-2 1-04
Page 32- 1 1
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
(
NOSE GEAR ASSEMBLY.
REMOYAL OF NOSE LANDING GEAR A N D ENGINE MOUNT. (Refer t o Figure 32-4.)
I . Remo\.e the engine cowling. (Refer t o Chapter 71.)
2. Remo\e the propeller. (Refer t o Chapter 61.)
3. Place the airplane on jacks. (Refer t o Chapter 7.)
Remo\e the engine. (Refer to Chapter 71.)
5 . Disconnect the two steering rods at the nose gear horn assembly by removing the cotter pins. nuts.
washers and bolts.
6 . Disconnect the oil lines. vacuum lines. fuel lines. hosesand wires which aresecured to the mount N irh
clamps and Koroseal lacing. Mark all wires and lines for identification and reinstallation.
7. Remove the nose gear and engine mount by removing the five bolts which attach the mount ro the
firewall.
4.
CLEANIXG. INSPECTIOS A N D REPAIR OF NOSE LANDING GEAR A N D ElVGINE hlOl'ST.
1 . Clean all parts with a suitable d p type cleaning solvent.
2 . Inspect the nose gear assembl! for the following:
A. Bolts. bearings and bushings for excess wear. corrosion and damage.
B. Strut housing and torque links for cracks. bends or misalignment.
3. The shimmy dampener requires n o service other than routine inspection. In case of damage or
malfunction. the dampener should be replaced rather than repaired.
4 . Repair to the landing gear is limited t o reconditioning of pans. such as replacing bearing and
bushings. smoothing out minor nicks and scratches. repainting of areas where paint has chipped or peeled and
replacement of pans.
INSTALLATIOK O F NOSE LANDING GEAR A N D ENGINE MOUNT. (Refer t o Figure 32-4.)
1 . Install the nose gear and engine mount assembly t o the firewall with bolts. washers and nuts. Torque
nuts a s specified in Torque Table. Chapter 91.
2. Attach the two steering rods t o the nose gear steering horn with bolts. washers and nuts.
3. If remo\.ed. connect the shimmy dampener t o the steering horn with bolts. washers and nuts. A spacer
bushing and cotter pin are required at the body attachment point.
4. Install the engine and connect controls. (Refer t o Chapter 71.)
5 . Attach hoses. wires and cables t o engine mount tubing. securing with clamps and Koroseal lacing
where required.
6. Check the alignment of the nose gear. (Refer to Alignment of Nose Gear.)
7. Remove the airplane from the jacks.
8. Install the propeller (refer t o Chapter 61) and engine cowling. (Refer t o Chapter 71.)
Revised: August
i1. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTEIVANCE MAIVL'AL
32-22-03
Page 32-13
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
ALIGNMENT OF NOSE GEAR.
I.
2.
3.
4.
Place the airplane on a smooth level floor that will accommodate the striking of a chalk line.
Place the airplane on jacks. (Refer to Chapter 7 . )
Le\.el the airplane laterally and longitudinally. (Refer to Chapter 8.)
From the center of the tail skid. extend a plumb bob and mark the contact point on the floor.
5 . Extend a chalk line from the mark on the floor below the tail skid t o a point approximatel!. three feet
forward of the nose wheel. Allow the line t o pass under the wheel a t the center line of the tire. S n a p the chalk
line.
6 . Ascertain that the rudder is properly rigged and the rudder cable tension is correct. (Refer t o Chapter
27.)
7 . Clamp the rudder pedals to align in a lateral position. (Refer t o Figure 3 2 - 5 . )
8. Ascenain that the nose wheel is in alignment with the longitudinal axis of the airplane or chalk line.
9. Install the steering assemblies between the steering horn and rudder pedals without any load on the
rods. Adjust the rod ends to obtain this no load condition. and connect the rods t o the steering horn.
- NOTE Check that the rod ends have sufficient thread engagement, bv use of
the check holes in $herods or a minimum of three-eighthsof an inch
thread engagement.
10. Ascertain that the rudder pedal stops are adjusted in accordance with instructions gli-en in Chapter
27.
I I . T o check the nose gear steering for its maximum right and left travel. mark on each side of the nose
u.heel an angle line from the center line and wheel pivot point. (Refer t o Chart 3202 for nose uheel turnlng
angle.) Turn the u.heel t o its maximum travel in both directions t o check for allowable travel. Should tra\el he
exceeded in one direction and not enough in the other direction. check for possible damage t o the pear fork or
torque links.
12. When the wheel is turned to its extreme right o r left travel. there should be .06 t o . I2 of an inch
clearance b e w e e n the nose wheel steeringstops. This is due to the stops on the rudder making contact ahead of
the nose gear stops. Prior to checking and o r making this adjustment. ascertain that the rudder tra\el I S
correct. (Refer t o Chapter 2 7 . )
I?. Adjust the shimmy dampener by turning the nose wheel against its stops and adjusting the rod end of
the dampener for adequate travel to both directions.
14. Remo\-e the aircraft from jacks.
32-22-04
Page 32-14
Revised: August 11. 1983
PIPER AIRCRAFT
PA-3;-301 /301T
MAINTENANCE .MANUAL
1641
RUDDER PEDAL NEUTRAL ANGLE
14" +3' - l o
Figure 32-5. Clamping R u d d e r Pedals
In Aeutral Position
Figure 32-6. R u d d e r Pedals at S e u t r a l Angle
C H . 4 R T 1202. S O S E G E . 4 R A L I G Y M E N T T O L E R A X C E S
-- I c
Rudder Pedal Keutral .Angle
.4f1 of \ ertical)
14 degrees
S o s e N'heel T r a ~ e l
24 degrees left
24 degrees right
~c
(
+
2C
+
ZC
32-22-04
Page 32-15
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
P cz9
CLEVELAND ( 4 0 - 9 0 A )
10
1 WHEEL ASSEMBLY
2 WHEEL HALF INNER
3 BEARING CUP
4 WASHER
5 WHEEL HALF OUTER
6 BEARING CONE
7 BRAKE DISC
B GREASE SEAL RETAINER
9 GREASE SEAL
10 SNAP RING
1 1 NUT
12 WHEEL THROUGH BOLT
13 DUST SHIELD
Figure 32-7. Main Wheel Assembly
WHEELS A N D BRAKES.
MAIN WHEEL.
REMO\'AL A N D DISASSEMBLY OF M A W WHEEL. (Refer t o Figure 32-7.)
I . Place the airplane o n jacks. (Refer t o Chapter 7.)
2. T o remove the main wheel. r e m o \ e the two c a p bolts that join the brake c!*linder housing and the
lining back plate assemblies. Remo\,e the back plate from between brake disc and wheel.
3. Remo\,e the dust co\.er. the cotter pin and flat head pin that safeties the wheel nut. and t he H heel nur.
Slide t h e wheel from the axle.
4. T h e wheel halves may be separated by first deflating t h e tire. With the tire sufficientl!. deflated.
remove the wheel through bolts. Pull the wheel halves from the tire by removing the inner half f r o m the rlre
first. a n d then the outer half.
5. T h e wheel bearing assemblies may be removed from each wheel half by first removing the snap rings
that secure the grease seal retainers. a n d then t h e retainers. grease seals and bearing cone. T h e bearing cups
should not be removed only for replacement a n d may be removed by tapping out e\.enly from the inside.
32-41-01
Page 32-16
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301 13011
MAINTENANCE MANUAL
a
ISSPECTIOS OF M A I S WHEEL ASSEMBLY.
I . \'isuall! check all parts for cracks. distortion. defects and excess wear
2 . Check i ~ ebolts fo; looseness o r failure.
3. Checb internal diameter of felt grease seals. Replace the felt grease seal if surface is hard or gritt!..
4. Check tire for cuts. internal bruises and deterioration.
5. Check bearing cones and cups for wear and pitting and relubricate.
6. Replace any w.heel casting having visible cracks.
ASSEMBLI' AND INSTALLATION O F MAIN WHEEL. (Refer t o Figure 32-7.)
I . Ascenainthat the bearing cup for each wheel is properly installed. Install the tire w.ith tube on the
outer wheel half and then , o i n the two wheel halves. Position the brake disc in the inner a,heel half and install
the through bolts with the nuts on the \al\.e stem side. Torque wheel nuts t o 150 inch-pounds and inflate tire
-(Refer t o Chapter 91.)
2. Lubricate the bearing cones and install the cones. grease seals and seal retainer rings. Secure with
snap rings.
3. Slide the wheel on the a s l e and secure with retainer nut. Tighten the nut to allow n o side pla!. !et
allon the w heel to rotate freel!. Safet!. the nut wmitha flat head pin. washer and cotter pin. Re~nstallthe dust
CO\ er.
4 . Position the brake lining back plates between the wheel and brake disc and the brake c! linder on the
torque plate. Insen the spacer blocks betwmeenthe back plates and cylinder. and install the four bolts t o secure
the assembl!.. I f the brake l ~ n ewas disconnected. reconnect the line and bleed the brakes. (Refer to Bleed~nf
Brakes.)
I NOSE WHEEL.
REMOYAL A S D DISASSEMBLY O F NOSE WHEEL. (Refer to Figure 32-8.)
I.
Jack the airplane enough to raise the nose wheel clear of the ground. (Refer t o Chapter 7 . )
2. If wheel fairing is installed. refer t o Removal and installation of Nose Gear Fairing.
3. Remo\e wheel by the following procedure:
A. Remole the nut and u.asher from one end of the axle rod and slide out the rod and axle plugs.
B. Lightl!. t a p the axle tube out from the center of the wheel assembl! b! use of a n object of near
equal diameter.
- NOTE Be certain not to damage the axle tube end in any way. This will
make removal and installation extremely dijficult.
C . Remake the spacer tubes and the wheel assembly.
D. Slide d0w.n uheel fairing and remove by turning
it sideways.
The wheel hal\.es may be separated by first deflating the tire. With the tire sufficiently deflated.
rem0t.e the u heel through bolts. Pull the wheel halves from the tire by removing the wheel half opposite the
\.al\.e stem first and then the other half.
5 . The wheel bearing assemblies may be removed from each wheel half by first removing the retainer
rings or snap ring which hold in the grease seal and seal retainers. and then the bearing cones. The bearing cup
should be rernwed by tapping out evenly from the inside.
4.
32-42-01
Page 32-1 7
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
P C24
CLEVELAND (40-778)
1 WHEEL ASSEMBLY
2 WHEEL HALF OUTER
3 BEARING CUP
4 WHEEL HALF INNER
5 BEARING CONE
6 GREASE SEAL
7 SNAP RING
8 WHEEL THROUGH BOLT
9 WASHER
1 0 NUT
11 GREASE SEAL RETAINER
-7
P c2s
McCAULEY ( 0 - 3 0 5 0 0 )
1 WHEEL ASSEMBLY
2 WHEEL HALF INNER
3 BEARING CUP
4 WHEEL HALF OUTER
5 BEARING CONE
6 GREASE SEAL RETAINER
7 GREASE SEAL
8 WHEEL THROUGH BOLT
9 WASHER
1 0 NUT
11 SNAP RING
!
.
Figure 32-8. Kose Wheel Assembly
32-42-01
Page 32-1 8
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
a
INSPECTIOS OF NOSE WHEEL ASSEMBLY.
1 . \'isuall! check all parts for cracks. distortion. defects and excess wear
2. Check tie bolts for looseness o r failure.
3. Check internal diameter of felt grease seals. Replace the felt grease seal if surface is hard o r gritty.
4. Check tire for cuts. internal bruises and deterioration.
5. Check bearing cones and cups for wear and pitting and relubricate.
6. Replace an!. wheel casting having visible cracks.
ASSEMBLI' AND INSTALLATIOK O F NOSE WHEEL. (Refer t o Figure 32-8.)
I . Ascertain that the bearing cup for eachwheel halfis properly installed. Install the tire with tube on the
wheel half with the v a h e stem hole and then join the two wheel halves. Install the through bolts with the
washers and nuts to the \,al\.e stem side. torque nuts t o 150 inch-pounds and inflate tire. (Refer t o Chapter 9 1 . )
2 Lubricate the bearing cones and install the cones and grease seal assembl!,. Secure with retainer rings
or snap rings.
3. Replace the wheel fairing by turning sideways and slipping it up over the fork assembl!..
4. Place the spacer tubes one on each side of the wheel and install unit in fork. Align and slide the axle
tube through the spacer tubes and wheel assembly. Reinstall the axle plugs and rod with washer and nut.
Tighten the nuts until no side play is felt. yet allowing the wheel t o rotate {reel!.
5 . Turn fairing so it w i l l fall into place and secure. (Refer t o Removal and Installation of Sose Gear
Fair~ng.)
a
I
BRAKES.
BRAKE ADJL'STMENT A N D LINING TOLERANCE.
S o adjustment of the brake lining clearance is necessaryas they are self-adjusting. Inspection of the lining
is necessari. and it ma! be inspected \.isually while installed on the airplane. Linings of the riveted type should
be replaced if the thickness of any one segment becomes worn below .099 of an inch or is une\-enly worn.
Linings of the "snap-on" heat.!, duty type should be replaced when the expansion gr0oi.e is n o longer \.isible.
REMOl'AL A S D DISASSEMBLY O F BRAKE ASSEMBLY. (Refer t o Figure 32-9.)
I. T o remo\e the brake assembl!.. first disconnect the brake line from the brake cylinder at the tube
fitting.
2. Remo\-e the two cap bolts that join the brake cylinder housing and the lining back plate assembl!..
Remo\.e the back plate from between the brake disc and wheel.
3. Slide the brake cylinder housing from the torque plate.
4. Remo\e the pressure plate by sliding it off the anchor bolts of the housing.
5. T h e piston may be removed by injecting low air pressure in the cylinder fluid inlet and forcing the
piston from the housing.
6 . Check anchor bolt for wear.
7 . Remo\e anchor bolt by the following procedure:
A . Position cylinder assembly o n a holding fixture. (Refer t o Figure 32-10. Step A.)
B. Use a suitable arbor press t o remove the.anchor bolt from the cylinder bod!..
32-43-02
Page 32-19
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
r~rs
1. BRAKE CYLINDER
2. PISTON
3 . O-RING
4. PRESSURE PLATE
-
6. LINING PRESSURE PLATE
6. RNET
7 . BACK PLATE
8. LINING BACK PLATE
9. RIVET
10 TORQUE PLATE ASSEMBLY
1 1 . BOLT-ANCHOR
12. WASHER
13 NUT
14. BOLT
15. BLEEDER SEAT
16. BLEEDER SCREW
17. BLEEDER CAP
18. ELBOW
-
NOTE
ON OLDER CYLINDERS (THOSE WlTH TAPERED HOLE AND BLEEDER SEAT) TORQUE
BLEEDER SEAT 7 5 TO 90 IN -LBS ON NEWER CYLINDERS (THOSE WlTH A STRAIGHT
TAPERED HOLE. BLEEDER SEAT HAS O-RING) TOROUE ONLY UNTIL O-RING SEALS
Figure 32-9. Brake Assembl!
8. install anchor bolt by the follow,ing procedure:
A . Support anchor bolt in a holding fixture. (Refer to Figure 32-10. Step B.)
B. Align cylinder bod! o\,er anchor bolt. (Refer to Figure 32-10. Step C.)
C. l!se a suitable arbor press and appl!- pressure on the spot face directly o\.er the anchor bolt hole.
(Refer to Figure 32-10. Step D.)
CLEANING. INSPECTION A N D REPAIR OF BRAKE ASSEMBLY.
1 . Clean the assembly with a suitable solvent and dry thoroughly.
2. Check the wall of the cylinder housing and piston for scratches. burrs. corrosion. etc.. that ma!
damage O-rings.
3. Check the general condition of the brake bleeder screw and lines.
4. Check the brake disc for grooves. scratches o r pits. Minimum thickness of Disc 164-20 used on \'heel
Assembly 40-868 is .205. (Refer to Figure 32-1 I . ) A single groove or isolated groo\!es up t o .O? I of an inch deep
would not necessitate replacement. but a grooving of the entire surface would reduce lining life and should be
replaced. Should it be necessary to remove the wheel disc. refer t o Removal and Disassembly of Main N'heel.
5 . Lining may be removed from the backing plates by drilling or punching out the old rivets. and
installing a new set using the proper rivets and a rivet set that will properly stake the lining and form a correct
flare of the rivet. (A rivet setting kit is available through Piper Dealers under Part Number 754 165.)
6. After replacing brake lining. they should be conditioned as follows:
A. For Cleveland brake no. 30-65. perform a minimum of six light pedal effort braking applications
from 25 to 40 MPH. allowing the brake discs t o partially cool between stops.
B. For CIe\-eland brake no. 30-83. perform three consecutive hard braking applications from 45-50
MPH. D o not allow, the discs to cool substantially between stops.
32-43-03
Page 32-20
Revised: August 11. 1983
I
PIPER AIRCRAFT
PA-32-301 1301T
MAINTEKANCE M A S I ' A L
ANCHOR BOLT
ANCHOR BOLT
STEP B
HOLDING FIXTURE
CYLINDER BODY
Fipurc 32-10, R r m o \ a l a n d Installation of A n c h o r Bolts
M I N I M U M THICKNESS
, 2 0 5 FOR 4 0 - 8 6 0 WHEEL ASSEMBLY
p t ,
MEASURE 2 OR 3 POINTS TO GET AVERAGE
DISC THICKNESS
32-43-03
Page 32-21
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
1. BRAKE RESERVOIR
2 RIGHT BRAKE AND RUDDER PEDAL
3 LEIT BRAKE AND RUDDER PEDAL
4 RIGHT BRAKE CYLINDER
5 LEIT BRAKE CYLINDER
6 BRAKE HANDLE
7 HANDLE RELEASE B U l l O N
8 MASTER CYLINDER ASSEMBLY
9 TORQUE TUBE
.
11 BOLT ASSEMBLY
12 CLEVIS PIN
13 LINE. INLET
'-1
. /'
J
Figure 32- 12. Brake System Installation
ASSEMBLI' A N D INSTALLATIOX OF BRAKE ASSEMBLY. (Refer t o Figure 32-9.)
I.
housing
2.
3.
Lubricate the piston O-ring w.ith fluid MIL-H-5606 and install o n piston. Slide the piston in c! linder
until flush u.ith surface of housing.
Slide the lining pressure plate onto the anchor bolts of the housing.
Slide the cylinder housing assembl! on the torque plate of the gear.
4 . Position the lining back plate betweenlhe wheel and brake disc. Install the two bolts to secure t h e
assembl! .
5 . Connect the brake line to the brake cylinder housing.
6 . Bleed the brake system. (Refer t o Bleeding Brakes.)
BRAKE MASTER CYLINDER.
REMOl'AL OF BRAKE MASTER CYLINDER ( H A N D BRAKE). (Refer t o Figure 32-12.)
I. T o remo1.e the brake master cylinder. first disconnect the inlet supply line from the fitting at the top of
the cylinder and allow. fluid t o drain from the reservoir a n d line into a suitable container.
2. Disconnect the pressure line from the fitting on the cylinder and allow. fluid t o drain from the c!.linder
line.
3. Disconnect the end of the cylinder rod from the brake handle by removing the cotter pin that safeties
the connecting cleiis pin. Remove the clevis pin and spacer washers.
32-13-06
Page 32-22
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
4 . Disconnect the base of the cylinder from its mounting bracket by remo1,ing the attaching bolt
assembl! .
5. The handle assembl\ ma\. be remo\,ed by removing
- the attaching
- bolt assembl!. that secures the
handle to its mounting bracket.
DISASSEMBLY OF BRAKE MASTER CYLINDER.
Remo\e the cylinder from its mounting bracket.
T o disassemble the c!.linder. first remove the piston rod assembly by remo\.ing the snap ring from the
slot at the rod end of the cylinder. Draw the piston rod assembl\' from the q l i n d e r .
The piston rod assembl! may be disassembled by first removing the small snap ring securing the
bushing. spring. piston. seal. gland. and. if desired. the large retainer spring.
4. Remo\e the O-rings from the piston and gland.
I.
2.
annular
3.
retainer
-
CLEANISG. INSPECTIOX A N D REPAIR OF BRAKE MASTER CYLINDER.
Clean the cylinder parts with a suitable solvent and dry thoroughly.
Inspect the interior walls of the q l i n d e r for scratches. burrs. corrosion. etc.
3 . Inspect the peneral condition of the fitting threads of the cylinder.
4. Check the piston for scratches. burrs. corrosion. etc.
5. Repalrs to the c!.linder are limited t o polishing out small scratches. burrs. etc.. and O-rings
I.
2
COUNTER BORE
1 HOUSING
2 SNAP RING
3 BUSHING. RETAINER
4 SPRING
5 O-RING
6 PISTON
7 DYNA SEAL
8 O-RING
9 GLAND. PACKING
12 ROD. PISTON
13 SPRING RETAINING
14 ROLL PIN
Figure 32-13. Brake Master Cylinder (Hand Parking Brake)
32-43-08
Page 32-23
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ASSEMBLY OF BRAKE MASTER CYLINDER.
-
NOTE
-
Use a small amount ojhydraulicfluid (MIL-H-5606)on the O-ring
and component parts to prevent damage and ease of handling
during reassemb&.
I. Install new O-ring on the inside and outside of the packing gland and on the outside of the piston.
(W'hen installing teflon O-ring on piston. it is recommended that it be installed with the use of a cone placed
against the piston. The cone may be constructed of plastic or metal with dimensions shown in Figure 32-13.)
2. T o assemble the piston rod assembly. install on the rod. in order. the roll pins. return spring retainer
washer. retaining spring. packing gland with O-rings. seal. piston with O-ring. spring and retainer bushing.
Secure these pieces with snap ring on the end of the rod.
3. Insert the piston rod assembl! in the housing and secure packing gland with snap ring.
4. Install the cylinder. (Refer to Installation of Brake Master Cylinder.)
INSTALLATION OF BRAKE MASTER CYLINDER (HAND BRAKE). (Refer t o Figure 32-12,)
1 . Install the brake handle assembly between its mounting bracket and secure with bolt. washers. nut
and cotter pin. H'ashers should be placed on each side of the handle. between the bracket. and under the nur.
2. Place the cylinder between the mounting bracket and secure the base end with bolt. washers. nut and
cotter pin. This. too. should ha\.e washers placed on each side of the cylinder and under the nut.
3. Connect the rod end of the cylinder t o the brake handle with a clevis pin and thin washers. Safet! the
cle\.is with a cotter pin.
4. Connect the pressure line to the fitting at the bottom of the cylinder.
5 . Connect the inlet suppl!. line to the fitting at the top of the cylinder and secure with spring clamp.
6 . Bleed the brake system. (Refer t o Bleeding Brakes.)
I
BRAKE CYLINDER (TOE BRAKE).
REMOVAL OF BRAKE CYLINDER (TOE BRAKE). (Refer t o Figure 32-14.)
1. Disconnect the upper and lower lines from the cylinder t o be removed and cap the lines to pre\ent
fluid leakage o r drain the fluid from the brake reservoir and master cylinder.
2. Remove the cylinder from its attachment fittings by first removing cotter pins that safety the c!.linder
attaching pins and then removing the pins.
DISASSEMBLY OF BRAKE CYLINDER.
Cleveland cylinder number 10-30. (Refer t o Figure 32-15.)
A . Remo\,e the cylinder from its mounting bracket. (Refer t o Remo\,al of Brake Cylinder.)
9 . T o disassemble the cylinder. first remove the piston rod assembly by removing the retaining ring
from the annular slot in the cylinder housing. Draw the piston rod assembly from the cylinder.
C. T h e piston rod assembly may be disassembled by first removing the retaining ring. slee\,e. spring.
and then the piston assembly. O-ring. and gland. and if desired. the return spring.
D. Remove the O-rings from the piston and packing gland.
1.
32-43-1 3
Page 32-24
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2. Gar-Kenyon cylinder number 17000. (Refer t o Figure 32-16.)
A.
Remove the cylinder from its mounting bracket. (Refer t o Removal of Brake Cylinder.)
B. T o disassemble the cylinder. first remove the piston rod assembly by unscrewing the fitting from
the cylinder.
C. The piston rod assembly may be disassembled by first removing the retaining ring securing the
sleeve and then remo\ing the spring. piston. seal. fitting. and if desired. the large return spring.
D. Remo\.e the O-rings from the piston and fitting.
CLEANING, INSPECTION A N D REPAIR OF BRAKE CYLINDER.
I. Clean the cylinder parts with a suitable solvent and dry thoroughl!.
2: Inspect the interior walls of the cylinder for scratches. burrs. corrosion. etc.
3. lnspect the general condition of the fitting threads of the cylinder.
4. Check the piston and valve for scratches. burrs. corrosion. etc.
5. Repairs to the cylinder are limited t o polishing out small scratches. burrs. etc.. and replacing \al\e.
washer. seal. and O-rings.
#
1a08
1. SPRING CLIP
2. TOE BRAKE PEDAL
3. ARM, TRIM CONTROL ATTACHMENT
4. CLEVIS PIN. WASHER 6 COTTER PIN
5. C L M S ASSEMBLY
6. CLEVIS PIN
7. ARM. IDLER
8. JAM NUT
8. CLEVIS PIN. WASHER 6 COlTER PIN
10. CLEWS PIN. WASHER & COTTER.PIN
1 1. SPRING. RETURN
12. BRACKn
13. BRACE ASSEMBLY
14. CVUNDER ASSEMBLY, HYDRAULIC
16. TUBE ASSEMBLY. LEFI
16. ClEvlS PIN & COnER PIN
17. HOSE ASSEMBLY FLEXIBLE
18. TUBE ASSEMBLY. RIGHT
-
Figure 32-14. Toe Brake Installation
32-43-14
Page 32-25
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
2637
1 HOUSING
5 O-RING
2.RETAINING RING
3.SLEEVE
4 SPRING
6.PISTON
9. O-RING
10 O-RING
1 I. WASHER WIPER
12. ROD
7. O-RING
8. GLAND
13.SPRING
14.WASHER
15.ROLL PIN
\
Figure 32-15. Brake Cylinder (10-30) (Toe Brake)
2037
'-eT/
Tsee
Note
On newer verslons the Roll Pin (14)IS deleted and rtem (1 3)IS a permanent shoulder rlng
"
(
d
1
2
3 4
561
8110
1 HOUSING
5 O-RING
9. O-RING
2 RETAINING RING
6 PISTON
10 O-RING
3 SLEEVE
7 SEAL
8 FfTTlNG
1 1 SPRING
4 SPRING
11
I1
13
14
13 WASHER
14 ROLL PIN
12 PISTON ROD
Figure 32-16. Brake Cylinder ( 17000) (Toe Brake)
Revised: August i1, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE M A N l J A L
ASSEMBLY O F BRAKE CYLINDER.
- NOTE -
Use a small amount of hydraulicfluid (MIL-H-5606)
on the O-ring
md component parts to prevmt &mage and tase of h m d h g
during reassembly.
I. Cleveland cylinder number 10-30. (Refer to Figure 32-15.)
A. Install new O-rings on the inside and outside of the packing gland and on the outside of the
piston.
B. T o assemble the piston rod assembly. install on the rod. in order. the roll pin. washer. spring.
wlasher. packing gland with O-rings. seal. piston assembly with O-ring. spring and roll pin.
C. lnsen the piston rod assembly in the cylinder and secure with the retaining ring.
D. Install the cylinder. (Refer to lnstallation of Brake Cylinder.)
2. Gar-Kenyon cylinder number 17000. (Refer to Figure 32-16.)
A. lnstall new O-rings on the inside and outside of the fitting and on the outside of the piston.
B. T o assemble the piston rod assembly, install on the rod. in order. the roll pin. return spring
retainer washer. return spring. fitting with O-rings. seal, piston with O-ring, spring and sleeve. Secure these
pieces with the retaining ring on the end of the rod.
C. lnsen the piston rod assembly in the cylinder and secure fitting.
D. lnstall the cylinder. (Refer to lnstallation of Brake Cylinder.)
INSTALLATION OF BRAKE CYLINDER. (Refer t o Figure 32-14.)
1. Position the cylinder at its mounting points and attach wire clevis pins. Safety the pins with cotter
- pins.
2. Connect the brake lines to the cylinder fittings.
3. Bleed the brakes.
BRAKE BLEEDIKG PROCEDURE (GRAVITY).
I
1. Attach a clean. clear plastic tube to the brake bleeder of the right landing gear. Extend the free end of
the tube to a container partially filled with hydraulic fluid (MIL-H-5606). Determine that the end oft he tube is
submerged in the fluid. Open the bleeder 112 t o I turn.
2. Fill the brake fluid reservoir with hydraulic fluid. It is located behind the left side access panel at the
forward baggage compartment.
3. Check to determine the right hand toe brake pcdal(s) in the cockpit have been pulled full aft.
4. Pull the hand brake handle and slowly pump the master cylinder approximately 50 times or until
hydraulic fluid is observed passing through the plastic tube a t the brake bleeder.
Fluid level in the reservoir must & maintained to prevvnt airfrom
entering the system.
5. Pump right brake cylinder very slowly approximately 12 times. This will purgeair from the toe brake
cylinder system. Watch for any air forced through the clear plastic tube during this operation to insureair has
been forced from the toe brake system.
6. Pump the hand brake an additional 25 times or until no air is observed through theclear plastic tube.
32-43-1 7
Page 32-27
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE M A N U A L
7. Tighten brake bleeder and remove the plastic tube.
8. Repeat Steps 1 through 6 t o the left main landing gear.
BRAKE BLEEDING PROCEDURE (PRESSURE).
1. Place a clean. clear plastic tube on the vent fitting on top of the brake fluid reservoir. Extend the free
end of the tube to a container partially filled with hydraulic fluid (MIL-H-5606). Be certain the end of the tube
is submerged in the fluid.
2. Attach another clear plastic tube t o the brake bleeder of the right landing gear. Connect the free end
of this tube to the pressure source. Open the bleeder 1 t o 2 turns and pressure fill the system with fluid.
3. With fluid continually flowing through the system. SLOWLY and simultaneously actuate the hand
brake and toe brake pedal. of the side being bled. several times to purge the cylinders of air. On dual brake
installations. both pedals for the brake being bled must be actuated.
,
-- NOTE
-
By watching the fluid pass through the plastic hose al the fluid
reservoir and the bleeder fitting on the gear being bled, it can be
determined whether any air is Iejt in the system. Ijair bubbles are
evident, filling of the system shall be wntinued until all the air is out
of the system and a steady j b w ofjluid is obtained Should the brake
handle remain spongy, it may be necessary to disconnect the bottom
of the toe brake cylinders (next to the pedal) and rotating the
cylinder horizontally or even above horizontal and by use of the
hand brake alone, purge the air from the systtm.
4. Close the open bleeder fitting to which the pressure hose is attached. D o not remove the tube from the
fluid reservoir until both brakes have been bled. Check the brakes on the side being bled for proper pedal
pressure. Replace cap on bleeder fitting.
- NOTE It may be necessary to rtmove any trwped a u in the top of the wheel
brake unit by applying pressure to the system with the brake hand
Iever and slowly opening the bkeder and release the hand Iever.
5. Repeat Steps 2 through 4 t o the left main landing gear.
6. Drain excess fluid from the reservoir to fluid level with a syringe.
BRAKE SYSTEM LEAK CHECK.
Pull for a good. firm hand brake and lock parking brake mechanism. Allow system to stand for
approximately I0 minutes. then by gripping the park brake handle it should not be able t o be pulled aft further
than the original set. Should the handle be able to be pulled towards the panel and feel spongy. a leak is present
at some point in the system. This leak may appear at any one of the connections throughout the system or
internally in the master brake cylinder or wheel brake assemblies.
32-43- 19
Page 32-28
Revised: August l I . 1983
PIPER AIRCRAFT
PA-32-30; /301T
MAINTENANCE MANUAL
BLEEDING O F BRAKES AFTER A UNIT IS CHANGED.
I. Actuate the hand brake handle until some pressure builds up in the system. At this time. crack the
attaching B nuts at any of the hose connections of the replaced unit. Most of the handle sponge feeling should
be displaced by this action.
2. Actuate the master cylinder and the toe brake cylinder of the side unit was changed and bleed fluid
through the brake assembly on the wheel by pumping pressure and cracking bleeder until pressure drops.
- CAUTION Do not allow pressure to bked ojj kjore ebsing bleeders, jor this
will allow air to enter the system. Repeat the pumping and bleeding
@proximately 10 or more times or until all the air treleasedjrom
the system. During all blnding, jhid level o j the reservoir must be
matrtained.
WHEEL FAIRINGS.
MAIN WHEELILANDING GEAR FAIRING REMOVAL A N D INSTALLATION. (Refer to Figure
3217.)
Remo\al of the main wheel fairing is a s follows:
A. Remove the bolt and washer securing the wheel fairing t o the wheel fairing support assembl\
B. Remove the two screws on the top of the wheel fairing. outboard of the landing gear fairing.
C . Loosen the eleven 1 4 turn fasteners securing the wheel fairing shell to the wheel fairing panel
and remo\.e the shell.
D. If removal of the wheel fairing panel is desired. remove the wheel fairing panel attachment bolt.
. Remove the panel.
2. Removal of the main landing gear fairing is as follows:
A. Loosen the eight (four inboard. four outboard) 1 , 4 turn fasteners which secure the forward
fairing half t o the aft fairing half.
B. Remove the six screws and washers securing the forward fairing half to the wing. Remo\e the
forward fairing half.
C. R e m o ~ ethe seven screws and washers securing the aft fairing half to the wing. Remove the aft
fairing half.
3. Installation of the main wheelilanding gear fairing is in the reverse of the removal procedure.
1.
32-81-00
Page 32-29
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE M A N V A L
1. NOSE GEAR FAIRING
2. FAIRING COVER FORWARD
3. FAIRING COVER - A n
4. STRUT FAlRlNG FORWARD
5. STRUT FAIRING - A n
6. BRACKET
7. SCREW AND WASHER
8. BOLT AND WASHER
9. SCREW AND WASHER
10. SHEU. MAlN WHEEL FAIRING
11. PANEL. MAlN WHEEL FAIRING
12. BOLT AND WASHER
13. ACCESS DOOR
14. SUPPORT ASSEMBLY. MAlN WHEEL FAIRING
15. BRACKET
16. BOLT. WASHER. NUT AND COTTER PIN
17. FORWARD FAIRING. MAlN STRUT
18 A F l FAIRING. MAlN STRUT
19. SCREW AND WASHER
20. 1/4 TURN FASTENERS
-
NOSE GEAR
FAIRING INSTALLATION
MAlN GEAR
FAIRING INSTAUATION
Figure 32-1 7 . Landing Gear Fairing Installation
32-81-00
Page 32-30
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
a '
NOSE GEAR FAIRITSG REMOVAL A N D INSTALLATION. (Refer to Figure 32-17.)
-
I. Remove the nose wheel fairing as follows:
A . Remove the four bolts (two on each side) securing the nose gear fairing to the strut assembly.
B. Remove the screws securing the forward and aft fairing cover assemblies to the nose gear fairing.
C. Slide the fairing up on the strut assembly to allow access to the nose wheel assembly.
D. Remove nose wheel as described in Removal and Disassembly of Xose Wheel.
E. Turn the fairing sideways and slide down and off of fork assemblv.
2. Remove the nose gear strut fairing as follows:
A . Remove the screws and washers which secure the forward strut fairing to the aft strut fairing.
B. Remove the screws and washers which secure the strut fairings to the fuselage. Remove the strut
fairings.
3. Installation of the nose gear fairing is in reverse of the removal procedure.
- END -
32-82-00
Page 32-31
Revised: August 11, 1983
I1
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PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
b
PIPER AIRCRAFT
1
I
I
PA-32-301 /301T
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEFT BLANK
a
CHAPTER
LIGHTS
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
-
CHAPTER 33 LIGHTS
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SLYBJ ECT
SUBJECT
GRID
KO.
EFFECTIVITY
GENERAL
Description and Operation
Troubleshooting
FLIGHT C O M P A R T M E K T
Instrument and Panel Lights
Dimmer Control Assembly
Removal of Dimmer Control Assembly
lnstallation of Dimmer Control Assembly
Switch Panel Assembly
Remo\.al of Switch Panel Assembly
lnstallation of Switch Panel Assembly
Annunciator Panel
EXTERIOR
Landing Light
Removal and lnstallation of Landing Light
Rotating Beacon
Remo\,al
lnstallation
Anti-Collision Light (Strobe)
Remo\.al of Wing Tip Strobe Light
lnstallation of Wing Tip Strobe Light
Removal of Strobe Power Supply
lnstallation of Strobe Power Supply
Troubleshooting Procedure
-
33 Cont./Effec.
Page 1
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-301 13011
MAINTENANCE MANUAL
GENERAL.
This chapter provides instructions relating to maintenance of lighting equipment used on this aircraft.
DESCRIPTION A N D OPERATIOIV.
1
To the left of the instrument panel on the cockpit side panel are electrical switches for the batter!. fuel
pump. anti-collision lights. landing light and pitot heat. The circuit breakers are located on the lower right
instrument panel as are a set of rheostat switches which control the radio. panel lights and navigation lights.
The annunciator panel includes alternator. low oil pressure and vacuum indicator lights. Also a n
overboost indicator light on the PA-32-3OIT. The annunciator panel lights are provided only as a warning to
the pilot that a system may not be operating properly. and that the applicable system gauge should be checked
and monitored to determine when or if any necessary action is required.
When checking the lighting system. the master switch must be on in order for the lights to operate. Insure
that the fuse which protects the light circuit being checked is serviceable.
CHART 3301. TROUBLESHOOTIKG (ELECTRICAL SYSTEM)
Cause
Trouble
Remedy
ANKUKCIATOR PAKEL
Blown fuse.
Replace 5 amp fuse
near the diode heat
sink.
No current from the
fuse to the resistor.
Check all wire segments
and connections.
Test switch fails to
activate warning lights.
Bad switch or
connections.
Check wires and replace
switch if necessar).
ALT warning light
fails to extinguish.
ammeter reads full
output.
Diode heat sink shorted
to airframe.
Replace teflon insulating
washers. D o not tighten
screws excessively.
ALT warning light fails
to extinguish.
Revised: August i l . 1983
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHART 3301. TROUBLESHOOTING (ELECTRICAL SYSTEM)(cont)
Trouble
Cause
Remedy
ANNUNCIATOR PANEL
All warning lights
fail to operate.
Blown fuse.
Replace the 5 amp fuse
behind instrument panel.
No current from bus.
Check all wire segments.
connections. and the
receptacle at the left
side of the annunciator
panel.
All the warning lights
fail to extinguish
after engine is running.
Test switch grounded
out.
Check terminals and
replace switch if
necessay.
011 warning light
fails to operate.
Bulb burned out.
Replace.
h'o current to sensor.
Check all wire segments
and connections.
Sensor activates at a
too low setting.
Replace.
Defective sensor.
Replace.
Sensor activates at a
too high setting.
Replace.
Sensor terminals
bridged.
Remove material
between terminals.
Defective sensor.
Replace.
Bulb burned out.
Replace.
Circuit in manifold
pressure gauge
defective.
Replace gauge.
OIL warning light
fails to extinguish.
OVER BOOST warning
fails to operate.
I
33-02-00
Page 33-02
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
0.
CHART 3301. TROUBLESHOOTING (ELECTRICAL SYSTEM) (cont)
Trouble
Cause
Remedy
AFiNUNCIATOR PANEL (cont)
OVER BOOST warning
fails to extinguish.
VAC warning light fails
to operate.
VAC warning light fails
to extinguish.
ALT warning light fails
to operate.
Press to test switch
shorted to ground.
Replace switch.
Circuit in manifold
pressure gauge
defective.
Replace gauge.
Bulb burned out.
Replace.
Fio current to sensor.
Check all wire segments
and connections.
Sensor activates at a
too low setting.
Replace.
Defective sensor.
-Replace.
Sensor activates at a
too high setting.
Replace.
Sensor terminals
bridged.
Remove material
between terminals.
Defective sensor.
Replace.
Bulb burned out.
Replace.
No current from bus
to resistor.
Check all wire segments
and connections.
Large diode shorted.
Replace.
Page 33-03
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
FLIGHT COMPARTMENT.
INSTRUMENT AND PANEL LIGHTS.
The instrument and panel lights are broken up into fivegroups: Upper Panel Lights. Lower Panel Lights.
Console Lights. Coupler Lights and Compass Light. T h e instrument lights are controlled by a 5 a m p circuit
breaker through a transistorized dimmer.
I
DIMMER CONTROL ASSEMBLY.
T h e dimmer control is located on the lower right instrument panel t o the right of the power quadrant.
There is one control knob connected to a variable resistor that controls the intensity of the instrument light$.
There is a second control knob connected t o a variable resistor which controls the light intensity for all the
avionic equipment. It may be necessary t o gain access t o the Dimmer Control Assembly: if srr follow the
instructions gi\en below.
REMOVAL OF DIMMER CONTROL ASSEMBLY.
I . Access to the Dimmer Control Assembly is from beneath the instrument panel.
2. Disconnect the electrical connection from the assembly.
3. Remo\e the two screws securing the assembly t o the instrument panel.
4.
Remo\e assembl!, from the airplane.
lNSTALLATION OF DIMMER CONTROL ASSEMBLY.
I.
slots.
Position the assembly in the instrument panel with the control knobs inserted into their appropriate
2. Secure the assembly t o the instrument panel with the two screws previously r e m w e d .
3. Connect the electrical connection t o the assembly.
4.
Check operation of Dimmer Control Assembly.
'
I SWITCH PANEL ASSEMBLY.
REMOVAL OF SWITCH PANEL ASSEMBLY.
1. Determine that power is removed from the circuit.
2. Locate and remoce the dimmer control knob o n the left side of the switch panel assembl!.
3. R e m o ~ ethe three screws which secure the cover assembly and remove the cover assembl!.
4. Remo\e the screws which secure the switch plate assembly t o the switch plate mount assemblies
5. Gently pull the switch plate assembly away from the cockpit side panel.
6. Kow that access t o the switches is attained they may be serviced as required.
33-13-01
Page 33-04
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
INSTALLATION OF SWITCH PANEL ASSEMBLY.
I . Determine that all electrical connections t o the switches are secure.
2. Place the switch plate assembly into position against the switch plate mount assemblies and secure
with screws.
3. Place the switch plate cover into position and secure with three screws pre\iously remo\,ed.
4. Reinstall the knob on the dimmer switch.
ANNUNCIATOR PANEL.
T h e annunciator panel is a small cluster of lights which warn of malfunctions in the various circuits or
systems. A malfunction is identified by the illumination of a n individual warning light. There are three warning
lights on the PA-32-30 I models and four warning lights o n the PA-32-301T models. Power is supplied from the
bus bar through a 5 a m p fuse located behind the circuit breaker panel.
The V A C warning light is controlled by a vacuum sensor switch located at the bulkhead and is attached to
the vacuum regulator. The sensor switch will activate when the differential pressure is below 3.5 in. Hg.
The 01L warning light is controlled by a n oil pressure sensor switch incorporated in the oil line to the oil
pressure gauge and is located at the bulkhead. T h e sensor switch will activate when the oil pressure is belo\\ 35
psi.
The A L T warning light is illuminated by current flowing from the bus bar t o the alternator circuit. T h i 9
condition exists when the alternator is not operating properly and the output is zero. During normal
operation. the alternator warning circuit is also supplied with power from the top diode terminal. This current
flows through a 5 a m p fuse. located above the diode heat sink. t o the resistor and diode creating a no-flou
condition which does not allow the warning light t o light.
T h e OVER BST warning light used on PA-32-301T is activated whenever the engine manifold pressure
reaches 35.5 to 35.8 inches of mercury. The manifold pressure sensor is incorporated in the manifold pressure
gauge.
An optional BAGGAGE DOOR warning light may be installed which will illuminate when the baggage
door is not secured.
The test button is used to check the operation of the lights when the engine is running. except for the
overboost light (PA-32-301T). the lights will work when the engine is not running and the master switch IS
turned o n .
EXTERIOR.
T h e landing and taxi light is contained in one light bulb. It is a 100 watt unit located within thenosecoul
section. The light is controlled by a switch t o a 10 a m p circuit breaker. The three naiigation lights are
controlled by a single switch and a 7.5 a m p circuit breaker. Optional anti-collision strobe lights ma! be
mounted o n each wing tip in the same assembly with the navigation lights. These units are rated t o flash at
approximately 50 times per minute.
I LANDING LIGHT.
33-4 1-00
Page 33-05
Revised: August i l , 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
REMOVAL A N D INSTALLATION OF LANDING LIGHT.
1.
R e m o \ e the screu, securing the clamp t o the bottom of the lamp.
2. Pull the lamp out and remove the two electrical leads connected t o it.
Take note of the wire placemmt on the lamp to facUitate
reinstallation.
3. T o install the lamp. reconnect the electrical leads and insert the lamp into position. then position the
clamp at the bottom and secure with appropriate screw.
ROTATING BEACON.
REMOVAL.
I . Loosen screw, securing clamp around rotating beacon lens. Remove clamp and lens.
2 . R e m o ~ elight bulb from bayonet socket.
.
To remove complete rotating beacon assembly, remove screws
securing it to fin tip. Next pull rotating beacon assembly out and
disconnect the electrical leads. Take note of their placement to
facilitate reinsfallation. Rotating beacon ossembiy con now be
removed.
INSTALLATION.
1 . Install light bulb in bayonnet socket.
2. Replace lens and clamp and secure by tightening screw on clamps.
AIVTI-COLLISIOIV LIGHT (STROBE).
The lights are located on each wing tip in the same assembly with the navigation lights. They are rated t o
flash at approximately 50 times a minute.
REMOVAL O F WING TIP STROBE LIGHT.
I. Remo\,e the screw- securing the navigation light cover and remove cover.
2. Remo\.e the three screws securing navigation light bracket assembly and pull out.
3. Remove the strobe lamp by cutting the wires o n the lamp beneath the mounting bracket
4. Remove the defective lamp.
5. Remove and discard the plug with the cut wires from its electrical socket.
33-43-0 1
Page 33-06
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
B916
L4F
ANTI-COLLISION SWITCH (BACK)
ANTI-COLLISION
[]B:::=LC;"
7 ayF:
BLACK (GND)
VIEW A
TO RIGHT WING
Figure 33- 1. Strobe Light Connections
33-43-01
Paae 33-07
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N b A L
INSTALLATION O F WING TIP STROBE LIGHT.
I . Route the wires from the new lamp down through the hole in the navigation light bracket.
2. Insert the wire terminals in the piastic plug supplied with the new lamp. ~ i r ;according t o the
schematic diagram located in the back of this section. Connect the plug t o the receptacle.
n
lamp o n navigation light bracket.
3. ~ o s i t ~ ostrobe
4. Secure na\.igation light assembly and bracket with appropriate screws.
5. Install na\.igation light cover and secure with appropriate screw.
R E M O V A L OF STROBE POWER SUPPLY.
The strobe power supply is in the aft section of the fuselage.
1 . Remo\.e access panel t o the aft section of the fuselage in the rear baggagecompartment t o gain access
t o power suppl!.
2. T o remove power supply disconnect the electrical plugs. (One t o four plugs depending on installation.
Make note of the placement of the plugs t o facilitate reinstallation.)
3. Disconnect the other electrical leads.
Make nore of rhe placement of the leads to jacilirare reinstallarion.
4.
Remo\.e the four screws securing pou,er supply t o the fuselage. Power supply can now be remo\ ed.
INSTALLATIOS O F STROBE POWER SUPPLY. (Refer t o Figure 33-1.)
I.
Position the p o u e r suppl! in place and secure with the four screws pre\iously remoied.
2. Reconnect the electrical leads in their proper place.
3. Reconnect the electrical plugs pre\iously removed in their proper place.
4.
Replace access panel in rear baggage compartment.
TROUBLESHOOTING PROCEDURE.
The strobe light functions a s a condenser discharge system. A condenser in the power supply is charged t o
approximately 450-\olts D C then discharged across the Xenon flash tube a t intervals of approximatel! 50
flashes per minute. T h e condenser is parallel across the Xenon flash tube which is designated t o hold off the
450-\olts D C applied until the flash tube is triggered by a n external pulse. This pulse is generated b! a solid
state timing circuit in the power supply.
When troubleshooting the strobe light system. it must first be determined if the trouble is in the flash tube
o r the power supply. Replacement of the flash tube will confirm if the tube is defective. A normally operating
power suppl! will emit a n audible tone of 1 t o 1.5 KHz. If there is no sound emitted. check the s!stern
according to the following instructions. When troubleshooting the system. utilize the appropriate schematic a t
the back of t h ~ ssection.
33-43-05
Page 33-08
Revised: August 11, 1983
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I. Ascertain the input voltage a t the power supply is 14-volts.
- CAUTION When disconnecting and connecting the power supply input
connections, do nor get the connectionsreversed. Reversedpolarity
o j the input vohagejor just an instmt will permantntly damage the
power supply. The reversed polarity destroys a protective diode in
the power supply, causing st&-destructionjrom overheating of the
power supply. This damage K sometimesnot immediately rrpparenr,
but will cause failure of the system in time.
2. Check for malfunction in interconnecting cables.
A. Ascertain Pins I and 3 of interconnecting cable are not reversed.
B. Using a n ohmmeter. check continuity between Pin I and 3 of interconnectingcable. If a reading
is obtained on the meter. the cable is shorted and should be replaced.
A short of the type described in Steps A and B will not cause
permanent damage to the power supply, but the system will be
inoperative U such a short exists. Avoid any connection between
Pins I and 3 of the interconnecting cable as this will discharge the
condenser in the power supply and destroy the trigger circuits.
- 4 A UTION
-
H'hen disconnecting the power supply, allow jive minutes oj bleed
down time prior to handling the unit.
3. Check interconnecting cables for shorts.
A. Disconnect the output cables from the power supply outlets.
B. The following continuity checks can be made with an ohmmeter.
C. Check for continuity between the connectors ofeach interconnectingcable b!.checking from Pin
1 t o Pin 1. Pin 2 to Pin 2. and Pin 3 t o Pin 3. When making these checks if n o continuity exists. the cable is
broken and should be replaced.
D. Check continuity between Pins I and 2. 1 and 3. 2 and 3 of the interconnecting cable. I f
continuity exists between any of these connections. the cable is shorted and should be replaced.
4. Check the tube socket assembly for shorts.
A . Disconnect the tube socket assembly of the anti-collision light from the interconnecting cable.
B. The f o l l o ~ i n gcontinuity checks can be made with a n ohmmeter.
C . Check for continuity between Pin I of A M P connector t o Pin I of tube socket. Pin 2 of A M P
connector to Pins 6 and 7 of tube socket and Pin 3 of A M P connector t o Pin 4 of tube socket. When making
these tests. if no continuity exists. the tube socket assembly is broken and should be replaced.
- END -
33-43-05
Page 33-09
•
1
PIPER AIRCRAFT
I
PA-32-301 1301T
MAINTENANCE MANUAL
I
THIS PACE INTENTIONALLY LEFT BLANK
a
CHAPTER
NAVIGATION AND PITOT/
STATIC
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE M A N U A L
-
-
CHAPTER 34 NAVIGATION A N D PITOT/STATIC
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTIOL
SL'BJ ECT
SUBJECT
GEKERAL
Description and Operation
Remo\al and Replacement of Face Mounted Instruments
G!ro Fitting Installation Procedure ( Edo-Aire)
Remoial and Replacement of Cluster Mounted
Instrumen!,
GRID
SO.
EFFECTI\'IT)'
2D 19
2D 19
2D 19
2DZO
2DZ I
I R 8-84
FLIGHT IKSTRL'METTS
Rate of Climb Indicator
Sen,iti\ e Altimeter
.41rspeed lnd~cator
G!.ro Horizon
Directional G!.ro
Magnetic Compas,
Adjustment of Compass
Turn and Bank Indicator
34
- Cont./Effec.
Page - 1
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
T h e instrument air system consists of pitot air and static air sources. T h e system supplies both pitot and
static air pressure for the airspeed indicator. altimeter and \.ertical speed indicator. These instruments are face
mounted.
DESCRIPTION A N D OPERATION.
(
T h e pitot air system consists of a pitot mast located on the underside of the left wing. with its related
plumbing. R a m air pressure entering the pitot is transmitted from the pitot inlet through hose and tubing
routed through the wing t o the airspeed indicator on the instrument panel. A partially o r completely blocked
pitot head will git,e erratic o r 7ero reading on the instruments.
Static air system consists of a static port located on the bottom of the pitot mast. T h e static port is direct I!
connected to I he airspeed indicator. altimeter and rate of climb indicator on the instrument panel b) means o f
hose and tubing routed through the wing along with the pitot line. An alternate static air source is located
below the instrument panel in front of the pilot. The alternate static source is part of the standard s!stem and
has a shutoff va1t.e which closes the port when it is not needed. A placard giving instructions for use is located
on the instrument panel. Pitot and static lines can bedrained through separate drain \,alves located on the left
low,er side of the fuselage interior.
REMOVAL A N D REPLACEMENT O F FACE MOUNTED INSTRUMENTS.
Since all instruments are mounted in a similar manner. a description of a typical remot.al and installation
is prot.ided a s a guide for the remot.al and installation of the instruments. Special care should be taken when
any operation pertaining to the instruments is performed.
I. Remot-e the face panel by removing the screws from around the perimeter of the panel.
2. H'ith the f x e panel removed. the mounting screws for the individual instruments will be exposed.
Rem0t.e the connections t o the instrument prior to removing the mounting screws of the instrument to bc
rem ot.ed.
Tag instrument connections for ease of installation.
3. Installation of the instruments will be completed by reversing the remo\,al instructions. After the
installation is completed and before replacing the instrument face panel. check all components for securit! and
clearance of the control column.
34-00-02
Page 34-01
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ZY RO FITTING INSTALLATION PROCEDURES (EDO-AIRE).
The use of teflon tape on the fitting threads is recommended and should be installed as follows:
- CAUTION Permit no oil, grease, pipe compound or any foreign material to
enterparts prior to installation ojfltings. Make sure that d air lines
are clean and free o j foreign particles and/or residue before
connecting lines to gyro. DO NOT USE THREAD LUBE ON
FITTINGS O R IN PORTS. The use 01thread lubt c m cause
contamination shortening the lifc of the gyro and can cause
premature failure. Any evidence of the use of thread lube will create
a WARRANTY VOID CONDITION.
I . Carefully lay teflon tape on the fitting threads allowing one thread to be visible from t h t end of the
fitting. Hold in place and wrap in the direction of the threads s o tape will remain tight when the fitting is
installed.
2. Apply sufficient tension while winding to assure that tape forms into thread grooves (one full wrap
plus I , 2 inch overlap is sufficient).
3. After wrap is complete. maintain tension and tear tape by pulling in direction of wrap. The resulting
ragged end is the key t o the tape staying in place.
4. Press tape well into threads.
5. Screw fitting into port careful not t o exceed torque requirements as noted on decal located on co\er of
p r o . (Refer t o Chart 9105 for specifications and Manufacturers address.)
Figure 34- 1. Pitot-Static System Installation
34-00-03
Page 34-02
Revised: August 19, 1980
PIPER AIRCRAFT
PA-32-301 1301T '
MAINTENANCE MANUAL
REMOVAL AND REPLACEMEST OF CLL'STER MOVNTED INSTRUMENTS.
A cluster. located o n the instrument panel. contains fibe individual instruments. Remo\al of these
instrument\ can be accomplished b! the follo\\ing procedure:
I . Remo\e the face panel by pulling the panel free from the retainers.
2. With the face panel remo\ ed. the clear plastic cover on the cluster assembly w ill be exposed. Remo\ e
the c o \ e r and cluster b! rcmo\ ing the two mounting screws.
3. Remo\e the connection t o the individual instrument t o be removed and remove the instrument from
the cluster assemhl!,.
4. Replace the instruments by re\,ersing the remo\al instructions. Check all mountings and connect 1on4
for securit!.
1
FLIGHT INSTRL'MENTS.
RATE OF CLIMB INDICATOR.
T h e rate of climb indicator measures the rate of change in statiq pressure when the airplane is climbing or
descending. By means of a pointer and dial this instrument will indicate the rate of ascent or descent of the
airplane in feet per minute. But due t o the lag of the instrument. the aircraft will be climbing or descend~ng
before the instrument starts t o read and the instrument wiH continue t o read after the aircraft has asburned I t \ el
flight. In rough air this should not be considered a malfunction.
C H A R T 3401. TROCBLESHOOTING (RATE OF C L I M B IKDICATOR)
Trouble
Cause
R emed !
Pointer does not set on
7ero.
Aging of diaphragm.
Reset pointer to 7ero
by means of setting
screu. T a p instrument
while resetting.
Pointer fails to respond.
Obstruction in static line.
Disconnect all instruments
connected t o the static line.
Clear line.
Static input frozen over.
Water in static line.
Check indi\.idual instruments for obstruction in
lines.
Obstruction in static input.
Clean lines and head.
34-10-0 1
Page 34-03
Revised: August 9, 1984
a
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
CHART 3401. TROUBLESHOOTIRG (RATE O F CLIMB IKDICATOR) (cont)
Trouble
I
Pointer oscillates.
I
I
Cause
Leaks in static lines.
Disconnect all instruments
connected t o the static line.
Check individual instruments for leaks. Reconnect
instruments to static line
and test installation for
leaks.
Defective mechanism.
Replace instrument.
Rate of climb indicates
when aircraft is banked.
Water in static line.
Pointer has to be set
before every flight.
Temperature compensator
inoperative.
Pointer cannot be reset to
zero.
Instrument reads very low
during climb or descent.
I
blow out lines from cockpit
out to pitot head.
I
I
Remedy
I
Diaphragm distorted.
I
Case of instrument broken
or leaking.
-NOTE -
I
Replace instrument.
c
Replace instrument.
I
Replace instrument.
When any connections in the static system are opened jor checking,
system must be rechecked per F.A .R. 23.1325.
SENSITIVE ALTIMETER.
The altimeter indicates pressure altitude in feet abovesea level. The indicator hasthree pointers and a dial
scale: the longer pointer is read in hundreds of feet. the middle pointer in thousandths of feet and the short
pointer in ten thousandths of feet. A barometric pressure window indicating inches of mercury is located on
the right side of the indicator dial and is set by the knob located on the lower left comer of the instrument. On
the left side of the indicator is a window which indicates barometric pressure in millibars. The altimeter
consists of a sealed diaphragm that is connected to the pointers through a mechanical linkage. The instrument
case is vented to the static air system and as static air pressure decreases. the diaphragm expands. causing the
pointers to move through the mechanical linkage.
34-10-02
Page 3404
Revised: May 21, 1980
PIPER AIRCRAFT
PA-32-301/301T
;
MAINTENANCE MANUAL
I
CHART 3402. TROUBLESHOOTING (ALTIMETER)
Cause
Trouble
Remedy
Excessive scale error.
Improper calibration adjustment.
Replace instrument.
Excessive pointer oscillation.
Defective mechanism.
Replace instrument.
High or low reading.
Improper venting.
Eliminate leak in stat~c
pressure system and check
alignment of airspeed tube.
Setting knob is hard to
turn.
Wrong lubrication or lack
of lubrication.
Replace instrument.
Inner reference marker
fails to move when setting knob is rotated.
Out of engagement.
Replace instrument.
Setting knob set screw
loose or missing.
Not tight when altimeter
was reset.
Tighten instrument screu,
if loose. Replace ~nstrument.
if screw is missing.
Cracked or loose cover
glass.
Case gasket hardened.
Replace instrument.
Dull or discolored
markings.
Age.
Barometric scale and reference markers out of synchronism.
Slippage of mating pans.
Replace instrument.
Barometric scale and reference markers out of synchronism with pointers.
Drift in mechanism.
Reset pointers, Refer
to the latest revision of
AC 43.13-1.
Altimeter sticks at
altitude or does not change
with change of altitude.
Water or restriction in
static line.
Remove static lines from all
instruments, blow line clear
from cockpit to pitot head.
+
34-10-02
Page 34-05
Revised: September i3, 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
C H A R T 3402. TROUBLESHOOTING (ALTIMETER) (cont)
Trouble
Cause
Remed!
Altimeter changes reading
as aircraft is banked.
Water in static line.
Remove static lines from all
instruments. and blow line
clear from cockpit t o pitot
head.
Altimeter requires resetting frequent ly.
Temperature compensator
inoperative.
Change instrument.
- NOTE When any connections in the static system are openedfor checking.
system must be rechecked per F.A.R. 23.1325.
AIRSPEED INDICATOR.
[
a
,-
The airspeed indicator pro\.ides a means of indicating the speed of the airplane passing through the air.
T h e airspeed indication is the differential pressure reading between ram air t o pressure and static air pressure.
This instrument has the diaphragm vented t o the pitot air source and the case is vented t o the staticair s!stcm.
As the airplane increases speed. the pitot air pressure increases. causing the diaphragm t o expand. X
mechanical linkage picks up this motion and moves the instrument pointer t o the indicated speed. The
instrument dial is calibrated in knots. and also has the necessary operating range markings for safe operation
of the airplane.
C H A R T 3403. TROCBLESHOOTING ( A I R S P E E D TUBES A N D INDICATOR)
1
Trouble
Cause
R emed!
Pointers of stick instruments d o not indicate
properl! .
Leak in instrument case o r
in pitot lines.
Check for leak and seal.
Pointer of instrument
oscillates.
Defecthe mechanism.
Replace instrument.
Instrument reads high.
Pointer not on zero.
Replace instrument.
Leaking static system.
Find leak and correct.
34-10-03
Page 34-06
Revised: August 9. 1984
PIPER A~RCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
C H A R T 3403. TROU BLESHOOTIKG (A1R S P E E D T O ~ E A
S N D INDICATOR) (cont)
Cause
Trouble
instrument reads low.
Airspeed changes a s aircraft
is banked.
Remedy
Pointer not o n zero.
Replace instrument.
Leaking static system.
Find leak and correct.
Pitot head not aligned
correctly.
Realign pitot head.
Water in pitot line.
Remove lines from static instruments and blow out lines
from cockpit to pitot head.
L
I
-- NOTE
-
When any connections in sratic sydetn are opened for eheckuig,
system must be checked per F.A.R. 23.1325.
GYRO HORIZOK.
The gyro horizon is essentially a n air driven gyroscope rotating in a horizontal plane and is operated b!
the same principal as the directional gyro. Due to the gyroscopic inertia. thespin axis continues to point in the
\mica1 direction. providing a constant visual reference to the attitude of the airplane relative to pitch and roll
asis. A bar across the face of the indicator represents the horizon and aligning the miniature airplane to the
horizon bar simulates the alignment of the airplane to the actual horizon. Any deviation simulates the
deviation of the airplane from the true horizon. .The gyro horizon is marked for different degrees of bank.
CHART 3404. TROUBLESHOOTING (GYRO HORIZOK IKDICATOR)
Trouble
Bar falls to respond.
Bar does not settle.
Remedy
Cause
Insufficient vacuum.
Check pump and tubing.
Filter dirty.
Clean or replace filter.
Insufficient vacuum.
Check line and pump.
Adjust valve.
Incorrect instrument.
Check p a n number.
Defective instrument.
Replace.
Page 34-07
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
a
CHART 3404. TROUBLESHOOTING (GYRO HORIZOF; INDICATOR) (cont)
Trouble
Bar oscillates or shimm~es
continuously.
Instrument does not indicate Iekel flight.
Cause
Remedy
Instrument loose in panel.
Tighten mounting screws.
Vacuum too high.
Adjust valve.
Defective mechanism.
Replace instrument.
Instrument not level in
panel.
Loosen screws and level
instrument.
Aircraft out of trim.
Trim aircraft.
-
Bar high after 180'
turn.
Sormal. if it docs not
exceed 1 !16 inch.
Instrument tumbles in
flight.
Low vacuum.
Reset regulator.
Dirty filter.
Clean or replace filter.
Line to filter restricted.
Replace line.
Plug missing or loose in
instrument.
Replace or tishtsn plug.
DIRECTIONAL GYRO.
The directional gyro is a flight instrument incorporatingan air driven gyro stabilized in the vertical plane.
The gyro is rotated at high speed by lowering the pressure in the air tight case and simultaneously allowing
atmospheric air pressure to enter the instrument against the gyro buckets. Due to gyroscopic inertia. the spin
axis continues to point in the same direction even though the aircraft yaws to the right or left. This relative
motion between the gyro and the instrument case is shown on the instrument dial which is similar to a compass
card. The dial. when set to agree with the airplane magnetic cornpus, provides a positive indication free from
swing and turning error. However, the directional gyro has no sense of direction and must be set to the
magnetic compass, since the magnetic compass is subject to errors due to magnetic fields. electric instruments,
etc. The directional gyro is only accurate for the heading it has been set for. If the gyro is set on 270°. for
instance. and the aircraft is turned to some other heading. there can be r large e n o r ktwecn the gyro and the
magnetic compass due to the error in compass compensation. This will appear as gyro precession. The gyro
should only be checked to the heading on which it was first set. Due to internal friction. spin axis error. air
turbulence and airflow, the gyro should be set at least every 15 minutes for accurate operation. whether it has
drifted or not.
34- 10-05
Page 34-08
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE MANUAL
CHART 3405. TROUBLESHOOTING (DIRECTIONAL GYRO INDICATOR)
Cause
Trouble
Excess drift in either
direction.
Remedy
Setting error.
Review paragraph titled
"General" for gyro operation.
Defective instrument.
Replace instrument.
High or low vacuum. If
vacuum is not correct,
check for the following:
1. Relief valve improperly adjusted.
. 2 . Incorrect gauge reading.
3. Pump failure.
4. Vacuum line kinked or
leaking.
1. Adjust.
2. Replace gauge.
3. Repair or replace.
4. Check and repair. Check
for collapsed inner wall
of hose.
Dial spins during turn.
Limits (55O
bank) or gimbal exceeded.
Recage gyro in level flight.
Dial spins continuously.
Defective mechanism.
Replace.
MAGNETIC COMPASS.
1
The magnetic compass is a selfcontained instrument. This instrument has an individual light which is
connected to the instrument lighting circuit. The compass correction card is located in the card holder
mounted on the instrument. The compass should be swung whenever instruments or radios are changed and at
least once a year.
ADJVSTMENT OF COMPASS.
Before attempting to compensate compass. every effort should be made to place the aircraft in simulated
flight conditions; check to see that the doors are closed, flaps in retracted position, engine running. throttle set
at cruise position and aircraft in level flight attitude. Aircraft master switch, alternator switch and all radio
switches should be in the Oh' position. All other cockpit controlled electrical switches should be in the OFF
position.
1. Set adjustment screws of compensator on zero. Zero position of adjusting screws is when the dot of
the screw is lined up with the dot of the frame.
2. Head aircraft on a magnetic North heading. Adjust N-S adjustment screw until compass reads
exactly h'orth.
34-10-07
Page 34-09
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
3. Head aircraft on a magnetic East heading and d o the same as Step 2. adjusting E-W adjustingscreu.
Head aircraft on a magnetic South heading and note resulting South error. Adjust 3 - S adjusting
screw until one-half of this error has been removed.
5 . Head aircraft on magnetic West and d o same as Step 4. adjusting E-W adjustment screw.
6 . Head aircraft in successive magnetic 30° headings and record compass readings on appropriate
deviation card. Deviations must not exceed 2 lo0 on any heading.
4.
CHART 3406. TROUBLESHOOTIKG (MAGKETIC COMPASS)
Trouble
Excessive card error.
Cause
Remedy
Compass not properly
compensated.
Compensate instrument.
External magnetic interference.
Locate magnetic interference and eliminate if
possible.
Excessive card oscillation.
Insufficient liquid.
Replace instrument.
Card sluggish.
Weak card magnet.
Replace instrument.
Excessive pivot friction o r
broken jewel.
Replace instrument.
Loose bezel screws.
Replace instrument.
Broken cover glass.
Replace instrument.
Defective sealing gaskets.
Replace instrument.
Discolored markings.
Age
Replace instrument.
Defective light.
Burned out lamp or broken
circuit.
Check lamp or contlnult) of
wiring.
Card sticks.
Altitude compensating
diaphragm collapsed.
Replace instrument.
Card does not move when
compensating screws are
turned.
The gears that turn compensating magnets are
stripped.
Replace instrument.
Compass swings erratically
when radio transmitter is
keyed.
h'ormal
Liquid leakage.
34- 10-07
Page 34-10
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE M A N U A L
TURK A N D BANK IKDICATOR.
The turn and bank indicator is electric. The turn portion of the indicator is a gyroscope. while the bank
portion of the indicator is a ball sealed in a curved glass tube filled with dampening fluid. There are two styles
of this unit. The first is the old style with a vertical needle in the center of the dial. This instrument reads only
the rate of turn. and unless the aircraft is turning. the needle will not move regardless of bank angle. The other
style is the turn coordinator which indicates both the rate of turn and rate of roll. With this indicator. if the
aircraft is rolled right and left rapidly. the indicator will move. indicating a turn. but if the aircraft is held in a
bank. and rudder is applied. the indicator will come back to zero indicating no turn.
C H A R T 3407. TROUBLESHOOTIh'G (TURK AKD B A h K INDICATOR)
Trouble
Cause
Remed!
Pointer fails to respond.
Foreign matter lodged in
instrument.
Replace instrument.
Incorrect sensitib it!.
Out of calibration.
Replace instrument.
Incorrect turn rate
(electric).
Out of calibration.
Replace instrument.
Aircraft not in coordinated
turn.
Center ball in turn.
Ball stick!.
Flat spot on ball.
Replace instrument.
Ball not in center M hen
aircraft is correctl!
trimmed.
Instrument not level in
panel.
Level instrument.
Instrument will not run
(electric).
KO power to instrument.
Check circuit and repair.
Instrument malfunction.
Replace instrument.
- END -
34- 10-08
Page 34-1 1
Issued: January 2, 1980
CHAPTER
OXYGEN
PIPER AIRCRAFT
PA-32-301 1301 T
MAIIVTEKANC'E MAIVUAL
CHAPTER 35 - OXYGEN
TABLE OF COSTENTS/EFFECTIVITY
CH.4PTER
SECTIOK
SUBJECT
SUBJECT
GRID
N 0.
EFFECTl\'IT'I'
GESERAL
Description and Operation
Troubleshooting
CRE\\' P.4SSESGER SYSTEMS
FIXED - Os!.gen System
lnspection and .Maintenance
Cleaning and Purging of Oxygen System Components
Sw,ageloc Fitting lnstallation
Application of Teflon Tape Thread Sealant
Leak Tests
Ox!._een S!.stem Component Handling
Remo\.al of Os!.gen Cylinder
Remo\.al of' Recharge Va1t.e
lnstallation of Recharge Va1L.e
lnstallation of Oxygen Cylinder
RemoLal and Installation of Pressure Gauge
Remo\.al of Outlets
Installation of Outlets
Remo\.al and lnstallation of Oxygen 03 O F F Control
Refilling Os!,gen System
PORTABLE - Oxygen System
Remo\.al of Ox!tgen Unit
Inspection and O\,erhaul Time
Testing for Leaks
Maintenance
Remo\.al of Outlets
Installation of Outlets
Purging Ox!$gen System
Cleaning of Face Masks
I-PO
9-8 l
8-80
-
35 Cont./Effec.
Page 1
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301 1301 T
MAISTENANCE MANUAL
GESERAL.
T h e purpose of the follou ing information is to protide supplemental information for the ser\ icing of the
ox!.gen systems. hlajor repair, to the os!.gcn systems should be accomplished by a n appro\.ed shop.
U'hen refilling any os!-gen c!.linder make sure to use only aiiation breathing os!,gen a s specified in MIL0 - 2 7 2 IOC .The moisture content of a\.iation osygen cannot exceed 0.005 milligrams of w,ater \.apor per liter o f
pas at 70° F and 29.92 inches of mercur!.
D E S C R I P T I O S A N D OPERATIOS.
Fixed o r portable os!,gen s\,stcms are a\.ailable for this aircraft. with the major components
manufactured by Scot1 A\,iation. It is therefore recommended that Scott Aviation as well a s Piper Customer
S e n i c e s be contacted for any further information not co\,ered herein.
The "fixed" os!.gen s!,stem uses a 3A.4 1800. 63.5 cu. ft. c!.linder. The cylinder. mounted in the tailcone
behind the baggage compartment. is connected t o a n external fill valve mounted to the left side of the fuselage.
aft of the fuselage bulkhead station 1 2 2 . 4 3 7 . The manifold for the outlets is arranged with the tank feed line
attached t o a tee fitting e n f he right rear passenger's outlet.and from where the other outlets are fed. see Figure
35-1. Push-pull control is pro\-ided b!- a knob on the o\.erhead panel. t o the left ofthe fresh air duct control. .4
gauge for displaling tank pressure is mounted in the o\,erhead duct behind the passengers. and is lighted b! a
post light.
The portable os!.gen s!,stem is made up of t w . 0 Scott units each invol\.inga 22cu. ft. capacity 3 h . 4 IROO
c\.linder. Each tank is incorporated in a case which utilizes a dual manifold. permitting four masks t o be used
(per unit) with dual connectors at each outlet.
D o not use grease or any type of grease jilting on anv oxygen system.
Hvhen working with an oxygen system make sure hands, clothing,
tools and immediate area are free of grease.
Oxygen cylinders are identified by the ICC or DOT identijication
stamped on the cylinder. The standard weight cylinder (ICC or DOT
3AA 1800) must be hydrostarical1.v tested every 5 years. The month
and year of the Iasr test is stamped beneath the ICCIDOT
iden fijication.
35-00-01
Page 35-01
Added: May 21. 1980
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
C H A R T 3501. TROL~BLESHOOTIKG(OXYGEN SYSTEM)
Trouble
No indication of pressure
on pressure gauge.
Cause
Cylinder empty or leak
in system has exhausted
pressure.
Remedy
Charge system and check
for Ieaks.2
Purge, charge, and check system
for leaks'
Pressure gauge or regulator
defective.
Return unit t o manufacturer or
take to approved sh0p.l
Replace gauge.'
Pressure indication normal but
no oxygen flowing.
Oxygen cylinder regulator
assembly defective.
Return unit to manufacturer or
take to approved shop.2
Remove tank and have regulator
removed. 1
Offensive odors in oxygen.
Cylinder pressure below SO psi,
Foreign matter has entered the
system during previous
servicing.
Purge the oxygen system.
4
NOTES:
( I ) Fixed system only.
(2) Portable system only.
L
35-00-02
Page 35-02
Added: May 21, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CREWIPASSENGER SYSTEMS.
- CAUTION -
Do not attempt to tighten any connections whUe the system is
charged.
Bottles which have been evacuated to Spsifor a significant length o j
time, or those that do not procluce an audibk hissing sound when the
valve is cracked, should be removed and hydrostatically tested. If
either of these conditions has existedfor a sig~&antkngth of time
it is also recommended that the @em be purged.
Make sure there is no oi4 grease, hydraulic fluid, or fuel in the
vicinity oj any fittings bemg serviced.
Do not use thread hbricants of any kind. Teflon tqpe (3MNo. 48)
should be used on TAPERED pbe threads without the tape
extending beyond the f&st thread, refer to dfective infomation in
this chapter.
Bejore working with the system make sure the abcrqft is ekctrically
grounded, and your hands and clothes are free of oil, grease, and
dirt.
FIXED OXYGEN SYSTEM.
Due to the nature of the process used to tests compressed gas tanks. servicing and hydrostatic test must be
conducted by a DOT or manufacturer (Scott Aviation) approved shop. The following material gives
recommended inspection and maintenance information for the various parts of the oxygen systems.
-- NOTE
-
Oxygen cylinders are identifed by the K C or DOT identflication
stamped on the cylinder. Thestandard weight cylinder (ICC or DOT
3A A 1800) must be hydrostatically tested at the end o j each 5 year
period. Lightweight cylinders flCC or DOT 3HT 1850) must be
tested every 3 years and be rrphced after 4380 refih or 24 years,
whichever mmesfirst. The month amdyeor of the last test should be
stamped on the cylinder beneath the ICC, DOT identification.
1. Check the outlets for leakage both in the use and non-use condition. and for leakage around an
inserted connector. For leak testing information refer to the appropriate subject in this chapter.
2. Check the high pressure gauge for accuracy by comparing its indicated pressure with that of a gauge
of known accuracy connected to the fill port.
35- 1Q02
Page 35-03
Added: Ma! 21, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
s nlGn PRESSURE OXYGEN LINE
6 OXYGEN BOTTLE
7 REGULATOR VALVE
Figure 35- 1 . Fixed Oxygen System Installation
B870
-
1 PLUG-IN cscon AVIATION PART NO 8570)
2 HOSE (1 /4" l D X 1 /2" 0 D X 18" LONG)
3 0-100 PSI PRESSURE GAUGE (ACCURACY 22%)
4 MASS FLOW GAUGE (0-5 UTERS/MIN )
4
3
I
1
I
2
FLOW T EST APPARATUS
1
I
PRESSURE TEST APPRATUS
Figure 35-2. Test Apparatus for Testing Oxygen System
35-10-02
Pact 35-04
Added: Mmy 21, 1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
3. Inspect tank for dents, bulges, corrosion, and major strap chaffing marks. Should any of these
problems exist, the tank should be removed and hydrostaticAlly tested.
4. An operational check of the regulator can be accomplished as follows; (Refer to Figure 35-2.)
A. Interconnect a sensitive pressure gauge of a range of 0 to 100 psi, with a Scott Aviation 857040
plug-in, and connect the apparatus to the pilots outlet in the overhead panel. It is recommended that a hose of
114 in. 1.D. x 112 in. O.D. and 18 inches long be used.
B. Interconnect a pneumatic flow apparatus of a range of 0-5 liters per min. (LPM). with a Scott
Aviation 8570-00 plug-in. Use the same hose dimensions as explained in the last step. Connect the flow
apparatus to the co-pilot's outlet.
C. Insen a Scott plug-in in each of the other outlets and pull the oxygen control knob to the on
position. The pressure and flow should be 55 to 80 psi and 3.3 to 5.3 (LPM) respectively, at sea level.
D. There should be no external leakage anywhere on the regulator when it is turned off, and all
fittings leak fret.
5. Check airframe log book for last maintenance on oxygen system and perform as required per Chart
3502.
6. Test the oxygen for odor. Pure oxygen is odorless and tasteless. Any system having a significant odor
present in the gas should be purged and the bottle replaced or-removed and purged.
7. Any fittings, connectors, and tubes which have imperfect threads, pitted or disfigured cones. or other
damage should be replaced.
-
CAUTION
-
Oxygen tubes must not be chmped to, or arpportd by ekctrical
wire bundks, h y d r d c , pneumatic ar other h e s .
8. Check plumbing for kinking, cracks, gouges, dents,deep scratches, or other damage; and. replace as
necessary.
9. Make sure to check the oxygen lines for proper clearance as follows; (Refer to Figure 35-3.)
A. Two inch minimum between oxygen tubes and allflrxibk moving parts of the aircraft (flexible
control cables. etc.). If enough space cannot be attained, protection from abrasion must be provided.
B. At least 11 2 inch minimum between oxygen tubes and all r i ' d moving parts of the aircraft such
as levers and rigid control rods.
C. Six inch minimum separation between oxygen tubes and hydraulic. fuel and electrical system
lines and components.
(1) When the six inch requirement cannot be complied with, one inch is allowed as long as
electrical cables and other lines arc supported at least every two inches; and. the oxygen
tubc(s) is protected by rubber neoprene hose fastened in place with cable ties at the location
the specific item crosses or is near the oxygen tube(s). If an item is near the oxygen tube for a
certain distance the oxygen tube for that distance must be covered.
D. A minimum of 118 inch between tubing and structure adjoining the supporting clamp as shown
in Figure 35-3, Sketch A.
E. Where a tube passes through a grommet, the tube must not bear on the grommet in any way that
might cause cutting of the grommet in service as shown in Figure 35-3, Sketch D.
F. While in service, items may receive vibrations causing them to come in contact with other pans
of the aircraft. With this in mind, low pressure tubing that is supported wellenough to prevent relative motion
must have at least a minimum clearance of 118 inch from a prpjector (bolt, nut, etc.). Low pressure tubing that
cannot be supported well enough to prevent motion must have a minimum clearance of I 18 inch allowed after
the maximum travel of the tube. High pressure lines are affected similarly but require 112 inch minimum
clearances. Refer to Figure 35-3, Sketch B.
10. Perform any other required maintenance as directed in AC43.13-IA, Chapter 8,
I I. Clean components as necessary per the following subject-paragraph.
351802
Page 3505
Added: M a y 21, 1980
•
PIPER A I R C R A F T
PA-32-301 /301T
MAINTENANCE MANUAL
I
0871
1 /8 MIN
1 /B MIN
1 / 8 MIN
SKETCH B
NEOPRENE HOSE MAY BE
SLIT TO FIT OVER TUBING
SECURE WITH MS3367
CABLE TIES POSITION SLIT
AWAY FROM WIRES ECT
GROMMET
CORRECT
INCORRECT
CLAMP WIRE BUNDLES
EVERY 2" AT CROSS-OVERS
Figure 35-3. Oxygen Tubing Installation
35- 10-02
Pact 35-06
Added: May 21. 1980
PIPER AIRCRAFT
PA-32301/301T
MAINTENANCE MANUAL
CLEANING A N D PURGING OF OXYGEN SYSTEM COMPONENTS.
-- CAUTION
PMI-)
-
Care must be exercised to prevmt contaminationojeomponents by
oil, grease, water, or foreign matter. Compressedair used in cleaning
and flushing tubes must be clean, dry filfered (oil free) air only.
I
I
Three met hods are recommended for cleaning oxygen system components.
I . Method I.
A. Vapor degrease part(s) with trichlorethylene.
B. Blow part(s) dry with a stream of clean, dry, filtered (oil-free) compressed air. or dry nitrogen.
Refer t o previous caution.
2. Method 11.
A. For tubing, flush with naptha per specification 'IT-hi-95.
B. Blow clean and dry off all solvent with clean, dry, filtered (oil-free) air. Refer to pre\ious
caution.
C. Flush with isopropyl alcohol.
D. Rinse thoroughly with fresh water.
E. Dry with air as described in previous caution or by heating at a temperature of 250" to 30OCFfor
one half hour.
Solvents may be reused provided they do not become excessively
contaminated with oil. This condition can be determined by
completely evaporating 100 mulih'ters of the liquid in a glass dish of
a determined weight. Evqporation may be occo~iishedby heating
the dish at 2OO0F/or one ha& hour. If @er evqporation and cool
down, the residue exceeds 100 milligrams in weight, the solvent
cannot be used for this purpose.
Method 111.
A. Flush with hot inhibited alkaline cleaner until free from oil and grease.
B. Rinse thoroughly with fresh water.
C. Dry thoroughly with a stream of clean air as described in the previous caution. or by heating 250
to 300°F for one-half hour minimum.
4. After cleaning, all tubing must be protected by caps, plugs, andior plastic bags.
3.
-- CA UTION
-
D o not use adhesive tqpe on oxygen conqwnentsfor attaching or
securing protective coverings. Usetudlow No. 6 waxedlacingtwine
or tie r q s .
5.
Before reinstallation make sure fitting. tube, and fixture threads are in good condition and that
the cones d o not exhibit pitting or disfigurement.
35-10-03
Page 35-07
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
SH'ACELOC FITTING INSTALLATIONS. (Refer t o Figure 35-4.)
- NOTE -
The high pressure line /itling at the regulator should be tightened
until it bottom. Make sure to use trflon tope on all male pipe
threads.
I. For swageloc fittings not preswaged o r for in-aircraft installation. proceed as follows:
A. Turn the fitting nut onto the fitting finger tight. and insen the tube until it bottoms firmly on the
shoulder in the fitting.
B. Tighten the nut with a wrench until the tube will not turn by hand.
C. Mark the nut at the six o'clock position.
D . Hold the fitting body steady with a backup wrench and tighten as follows:
( I ) On tubing with a diameter bigger than 3: 16 inch, tighten 1 1 1 4 turns ( t o the nine o'clock
position).
(2) On tubing of 1,' 16. 1.8.and 3; 16 inch diameter tighten only 3;4 turn.
E. If nut and tube must be disconnected from the fitting, reconnect by seating the tube on the
shoulder of the fitting and tightening the nut finger tight. Follow u p by tightening the nut with a wrench. one
quarter turn (if absolutely necessary the original 1 1 !4 or 314 tight position) and then snug with wrench.
2. Preswaged swageloc fittings are fabricated and installed as follows:
A. Assemble the nut and ferrules finger tight o n the preswaging tool and insert the tube until it
firmly bottoms on the shoulder in the tool. T h e preswaging tool can be attained from Crawford Fitting
Company. refer t o List of Consumable Materials in Chapter 91.
B. Tighten the nut on the fitting just enough that the tube within the fitting will not turn by hand.
C. With a wrench tighten the nut as follows:
( I ) On tubing with diameters over 3: 16 inch. tighten 1 1:4 turns.
(2) On tubing with 1 . 16. 1,8. or 3; 16 inch diameter tighten 3;4 of a turn.
D. Unscrew the nut to release the ferrule-tube assembly from the tool.
E. The assembly is installed on the fitting as follows:
( I ) Slide tube in fitting until it bottoms, turn nut t o finger tight position. and tighten one
quarter turn with wrench.
(2) Snug slightly with wrench.
APPLICATION OF TEFLON TAPE THREAD SEALANT.
CIYOO(~~
All male pipe (tapered) threads of the oxygen system should be sealed with 3M No. 48 teflon tape. Teflon
I tape should not be used on straight threads. N o other lubricants shall be used in place of the teflon or on any
other threads.
I . Wrap tape on the threads. starting with those farthest from the opening. in the direct ion of the thread
spiral. Circle the threads. making sure that each side of the tape has a slight overlap.
2. Wrap the tape such that it does not extend beyond the last thread on the fitting at the opening. The
tape should then be pulled till it separates. D o not cut tape, it will not stick properly.
35-10-05
Page 35-08
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MAK1'AL
STEP 1
TURN THE FlTnNG NUT ONTO THE FlTTlNG FINGER
fKiHT AND INSERT THE TUBE UNTIL K BOTTOMS
FIRMLY ON THE SHOULDER IN THE FITTING
STEP 2
MARK THE NUT AT THE SIX O'CLOCK POSITION.
STEP 3
HOLD THE M I N G WITH A WRENCH AND TIGHTEN
THE FRfING NUT AS FOLLOWS:
a. TUBING W H A O U M n E R . GREATER THAN
3/16th INCH SHALL BE TIGHTENED 1-'A TURNS
( m E NINE O'CLOCK POSITION).
b. TUBING WKH A DIAMETER OF 1/IS. 1/8 OR
3/16 INCH S H A U BE TIGHTENED ONLY 3/4TURN.
J
I
Figure 35-4. Installation of Swagelock Fittings
35-10-05
Page 35-09
Added: Ma! 21. 1980
.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MAYUAL
CHART 3502. OXYGEN SYSTEM COMPONENT LIMITS (FIXED)
Parts
Regulator
Pressure Gauge
High Pressure Lines
Low Pressure Lines
Outlets
External Recharge Valve
Masks
I
2
Inspection
300 Flight
300 Flight
300 Flight
300 Flight
300 Flight
Each Use
Each Use
Hours
Hours
Hours
Hours
Hours
Overhaul
5 yrs.
Replace on Condition
Replace on Condition
Replace on Condition
Every 5 years'
Every 5 years2
Replace as necessary
On condlt~on.replace the rubber components In the arscmbly or replace aucmbl)
If the screen In from of \al\e IS dm!. replace balbe Valve replacement a recommended wery 5 years
A
LEAK TESTS.
P ~ W U ~ F
Solutions recommended for leak testing are Leak-Tec Formula #16-OX. and that available from Scott
Aviation. Refer to the List of Consumable Materials for consumer information.
I . Remove the royalite covers in the baggage compartment and, with oxygen system turned off.
disconnect the low pressure supply line and connect it t o a regulated cylinder charged with dry nitrogen.
- NOTE Whenever a leak check is performed, alljitting connections as well
as other questionable areas, should be inspected
2. Apply the leak detector solution to the test surface and watch for indication of leakage.
3. Large leaks will produce bubbles immediately. but small leaks will form a white foam in 5 to 60
1 seconds.
4. With outlets vacated of masks. connect a test pressure gauge to the co-pilot's outlet as described in the
subject paragraph on Inspection and Maintenance, see Figure 35-2.
5. Adjust the regulator on the dry nitrogen cylinder for 100 psi and check for leakage at the outlets.
6. Correct any leaks and wipe off excess leak detector solution.
7. Close the valve on the nitrogen gas tank and insert a Scott plug-in t o relieve system pressure.
8. Disconnect test gauge, plug-in, and nitrogen tank.
9. If the oxygen cylinder is not t o be hooked up or installed immedktely, cap and cover the exposed
fittings with new clean plastic bags. Temporarily support lines as needed to prevent damage. Make sure caps
and coverings are as clean as possible.
35-10-06
Page 35-10
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
OXYGEN SYSTEM COMPONENT HANDLING.
Keeping in mind the effect of compressed oxygen on materials. oxygen system components must be
handled carefully. Pons on regulators. indicators. and other opened components must also be kept capped or
plugged t o prevent ingestion of foreign material. Adjustments or modifications should only be initiated upon
approval of the FAA. Piper. or Scott Aviation.
REMOVAL OF OXYGEN CYLINDER. (Refer to Figure 35-5.)
-- NOTE
-
Replocement time for the recharge valve is wery 5 years. If the
cylinder is being removed for the 5y-r test, it is recommended the
vatve be removed and/or replaced at the some time.
The oxygen bottle. located behind the finished bulkhead in the baggage compartment. is secured to a
removable shelf mounted to each side of the fuselage. The tank is mounted such that the regulator-control
valve is on the left side of the aircraft. the same side as the recharge valve. A shroud also covers the regulator
end of the bottle to prevent leaks, should any develop, from filling theaircraft with oxygen. With this in mind.
a vent tube interconnects the shroud with the recharge valve fixture permittingany oxygen to vent overboard.
1. Remove the screws attaching the finished bulkhead t o the fuselage bulkhead. and remove the finished
bulkhead.
2. It is recommended that when working in the rear of the aircraft. an appropriate tailstand be properly
attached to the tail.
3. With the immediate area clear of flammables (grease, hydraulic fluid. fuel). and oxygen system off.
connect a mask of tube to an outlet to exhaust any pressure in the system.
4. Remove the screws and loosen the clamps securing the shroud to the cylinder and regulator-control
valve.
5. Remove the spring clamp securing the vent tube to the cylinder shroud and disconnect the tube.
6. Carefully separate the shroud along the high pressure lines.
7. The high pressure fitting on the regulator~ontrolvalve incorporates a valve that opens only when a
line is connected with it. With this in mind. carefully unscrew the high pressure line until the pressure decreases.
and then remove the line. Disconnect low pressure lines as well.
8. Loosen and open the clamps securing the bottle to the shelf. Carefully move the bottle in such a way
the fair access can be made to control mechanism.
9. Disconnect the control cable. Be careful not to kink the cable.
10. Remove the tank from aircraft being careful not to damage the regulator-control valve.
35-10-08
Page 35-11
Added: May 21, 1980
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE M A N U A L
1181
1. REGULATOR VALVE
2 OXYGEN CYLINDER
3 SHROUDCLAMP
4. SHROUD CLAMP
5. SHROUD
6. CONTROL CABLE
7 . LOW PRESSURE
8 HlGH PRESSURE
9. OXYGEN
CYLINDER
CLAMP
-
Figure 35-5. Oxygen Cylinder and Regulator Assembl!
4
X
1185
I
I
CAUTION
I
I
i
ASCERTAIN THAT REGULATOR VALVE IS CLOSED
BEFORE DISCONNECTING HlGH PRESSURE LlNE
FROM RECHARGE VALVE
I
I
5
I
I
j
I
TOROUE 30 (MIN ) TO 1SO (MAX 1 IN - U S
I
1 VENT TUBE
2 RECHARGE VALVE SHROUD
3 RECHARGE VALVE ASSEMBLY
I
4 RUBBER GROMMET
5 RECHARGEVALVE ACCESS
6 DISH ASSEMBLY
A
7 HIGH PRESSURE LINE
,
Figure 35-6. Ou!gcn S!stcm Rccharge Val1.e Installation
35-10-08
Pate 35-1 2
Revised: August 19, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
REMOVAL OF RECHARGE VALVE.
The recharge valve is located on the left rear side of the aircraft and is covered by its own access door. The
valve is interconnected with the gauge line a s well as the regulator-control valve and is constantly under
cylinder pressure as long as the high pressure line is attached to the regulator.
-
NOTE
-
The recommended service w efor the recharge valve is 5 years, and
the oxygen cylinder must be hydtostatically tested every 5 years.
With these circumstances in mind it is recommended that the
recharge valve be removed and replaced when the cylinder is
removed for service.
I. Due to the location of the recharge valve it is necessary to. remove the oxygen cylinder. For ease of
removal it is recommended that the cylinder shelf also be removed.
2. Remove the screws that secure the recharge valve's protective shroud to the valve mounting dish. and
slide the shroud back over the high pressure line.
3. Unscrew the high pressure line fitting from the recharge valve and with somebody turning the screw
from outside the aircraft. backup the nut to remove the valve.
INSTALLATION OF RECHARGE VALVE.
I . Insert the valve through the aperture in the mounting cup and align the bolt holes.
2. With the safety chain and information platemounting washer aligned at one of the holes, install the
mounting bolts.
3. Apply teflon tape to male threads as explained earlier in this section.
4. Reconnect the high pressure line to the valve and torque the fitting 30 in.-lbs. min. to I50 in.-lbs. max.
(Refer to Figure 35-6.)
5. Reinstall the valve protective shroud.
INSTALLATION OF OXYGEN CYLINDER.
I
1. Before mounting the cylinder to the shelf, connect the control cable to the control valve-regulator. If
the shelf has been removed reinstall it before continuing. Install teflon tape per prior instructions in this
chapter.
2. Position cylinder on shelf and install the pressure lines. Insert tubing into fitting until ferrule seats in
fitting. Tighten the nut by hand and then one quarter turn with a wrench. If fitting is relatively new the nut
might be turned 314 of a turn. Follow up by snugging the nut slightly with a wrench.
3. Install the cylinder protective shroud and tighten the clamps securing it to the tank and valve.
4. Secure the cylinder to the shelf by connecting and tightening the damps.
5. If vent tube has been disconnected from the shroud make sure it is firmly attached to both the cylinder
and valve shrouds.
6. Make sure all seals are properly in place in the cylinder shroud. Make sure the MS35489-35 seal is in
the bottom of the shroud where the low pressure line comes through. The two seals where the high pressure
lines go into the shroud are MS35489-2 grommet seals.
7. Check pressure and refill bottle as necessary.
8. Inspect for leaks, especially at fittings that have been separated.
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 / M l T
MAINTENANCE MANUAL
Baa7
ADD AN960-8 OR A
BRACKET FORE AND A n .
1. OXYGEN PRESSURE GAUGE
POST LIGHT
OXYGEN GAUGE FITTING
DUCT WORK
OXYGEN GAUGE COVER
GAUGE SUPPORT BRACKET
HIGH PRESSURE LINE
RETAINING CLIP. SNAP-IN
HATSHELF BULKHEAD
OXYGEN GAUGE RETAINING BRACKET
2.
3.
4.
5.
6.
7.
8.
9.
10.
1
3
J
Figure 35-7. Oxygen Pressure Gauge Installation
THIS SPACE INTENTIONALLY LEFT BLANK
35-10-1 1
Page 35-14
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
REMOVAL A N D INSTALLATION OF PRESSURE GAUGE. (Refer to Figure 35-7.)
1. Removal of the oxygen pressure gauge as follows:
A. The pressure gauge is tied into the same high pressure line as the recharge valve by means of a teefitting at the tank regulator-control valve. A check-valve in the tank regulator control valve is depressed upon
installation of the high-pressure line allowing oxygen to enter the system. With the tank valve in the off position. disconnect the high pressure line from the tank valve, slowly, to allow the line pressure to bleed-off. Cap
the line as soon as possible after removal.
B. Remove the snap-in retaining clips which secure the oxygen gauge cover to the overhead vent
panel and remove the cover.
C. Disconnect the high pressure line at the rear of the oxygen pressure gauge and cap the line.
D. Remove the hex nuts from the studs on the rear of the gauge and remove the gauge.
E. If the fitting on the rear of the instrument is to be reused, remove. clean threads. and using teflon
tape install fitting on new gauge. Refer to appropriate section this chapter.
2. Installation of the oxygen pressure gauge is as follows:
A. With the fitting installed on the rear of the gauge place the gauge in the support bracket. place the
retaining bracket into position over the rear of the gauge and secure with hex nuts.
B. Wrap teflon tape on threads of fitting (see appropriate section. this chapter) and install o x g e n
line.
C. Reattach oxygen line fitting to tank.
REMOVAL OF OUTLETS.
I . Make sure the oxygen system iscompletely turned off. Insert a n oxygen mask to release pressure. and
insure the system is off.
2. With a suitable spanner wrench. remove the outer half of the outlet.
3. Remove the screws retaining the trim panel and remove same.
4. The outlet can now be disconnected from the low pressure line(s). Make sure to cap lines immediately
after disconnection.
INSTALLATION OF OUTLETS.
1. Apply teflon tape to male threads of the affected fitting. Refer to appropriate procedure in this
chapter.
2. Connect the outlet to the low pressure line.
3. Position the trim panel and secure with screws.
4. Position and secure the outer half of the outlet with a suitable spanner wrench.
5. Torque the fittings onto the outlets to approximately 30 in.-lbs. Do not overtorque.
35-10-14
Page 35-15
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
a
REMOVAL AKD INSTALLATIOS OF OXYCEN ONIOFF CONTROL. (Refer to Figure 35-1.)
1. As shown in Figure 35-1. the on off control is mounted in the overhead vent panel. To remove the
control. drop the overhead panel and ducting and remove the retaining nut from the rear of the control cable
fitting.
2. Make access to the bottle: if necessary. and disconnect the cable from the regulator-control
mechanism.
3. Cut the tie-raps and securing the cable and pull cable from aircraft.
4. When installing a new cable. make sure new cable shield is cut to 113.5 inches long and that the core
has sufficient material to make a twin loop. two inches from the end of the shield, Install as follows:
A. Route cable through the hole in the overhead duct and as shown in Figure 35-1. Tie-rap the cable
as before.
B. Make sure the cable properly reaches the valve and reinstall vent and panels. Reconnect cable to
control mechanism.
REFILLING OXYCEN SYSTEM.
Before servicing the oxygen system make sure the aircrajt is securely
grounded electrically.
D o not attempt to tighten any connections while the system is
charged.
D o not operate on electrical equipment while servicing oxygen
system.
Refilling of oxygen systems should be done by qualified personnel. For comparison of filling pressures to
ambient temperatures. refer to Chan 3503. The following are parameters to be followed for filling.
1. Only aviators breathing oxygen (MIL-0-27210) and appropriate filling equipment should be used to
fill the system.
CHART 3503. FILLING PRESSURES FOR CERTAIK AMBIENT TEMPERATURES
Ambient Temperature
0
10
20
30
40
50
60
NOTE:
Filling Pressure
Ambient Temperature
Filling Pressure
1650 (PSI)
70
80
90
100
110
120
130
1975 (PSI)
2000
2050
2100
2 150
2200
2250
1 700
1725
1775
1825
1875
1925
Filling pressures are for 1850 PSI at 70° F. Table assumes 25O F rise due to heat of compressor with max. fill rate.
35-10-16
Page 35-16
Revised: August 19, 1980
PIPER AIRCRAFT
PA-32-301/%IT
MAINTENANCE MANUAL
2. If a cylinder has less than 5 psi pressure or has insufficient pressure to produce an audible hissing
sound when the valve is cracked, it should be removed andlor purged, and if the condition has existed for a
significant length of time, hydrostatically tested.
3. Make sure both the charge valve and recharge "cart" fittings are clean and free of contamination.
- WARNING -
BE CERTAIN THERE IS NO OIL ON THE FIl7INGS O R
NEAR THE IMMEDIA TE VICINITY.
I
4. Attach service cart hose to recharge port. Fill the system at a rate not exceeding 200 psig per minute
proceeding as follows:
A. To obtain the correct filling pressure for the oxygen system at various ambient temperatures. a
table is included for your convenience. The pressures given are not exact, but sufficiently accurate for practical
purposes of working pressures between 1800and 2400 psig cylinders. The cylinder should be allowed to cool to
a stabilized temperature after filing before checking against the values in Chan 3503.
B. When using a recharge unit consisting of one supply cylinder, slowly open the valve of the supply
unit and allow the oxygen to transfer.
C. When using a recharge unit consisting of two or more supply cylinders(cascade storage system).
it is recommended that the following procedure be used:
( 1) Before opening any valves. check the pressure remaining in the airplane's oxygen cylinder.
If it is still partly charged, note the pressure indicated onthe cylinder gauge. Then open and
close each valve on the cascade storage system and determine which cylinder has the lowest
pressure. When found if this cylinder has a pressure lower than the oxygen cylinder in the
aircraft, do not attempt using it for filling; use the storage cylinder that has a pressure
higher than the aircraft's cylinder but lower than the others.
(2) Open the valve on only the one storage cylinder with the lowest pressure. When the pressure
indicated on the aircraft's oxygen gauge and charging gauge has become equal. close the
valve of the storage cylinder; then go to the storage cylinder with the next higher pressure
and repeat the procedure.
(3) If after using the last storage cylinder the aircraft's oxygen system is still not fully charged. a
full storage cylinder should be put in place of a cylinder with the lowest pressure and used in
the same manner.
(4) A good deal of oxygen will remain in the large cylinders used in the cascade system after
filling only one of the cylinders but such remaining oxygen will be at a pressure something
less than the 1850 psi which is not sufficient pressure to completely refill another aircraft
cylinder, although it will refill several small cylinders.
(5) I t is not economical even on a three or four cylinder cascade system to begin recharging
with oxygen at less than 300 psi pressure in the 300 cubic foot bank of cylinders. So use 300
cubic foot cylinders down to approximately 300 psi; then return for refilling. In two
cylinder systems use to approximately 100 psi; then return for filling.
D. When the pressure gauge on the recharge unit or in the aircraft reaches 1800 to 1850 psi, close the
pressure regulator valve on the recharge unit. Disconnect the filler hose from the filler valve; replace the
protective cap on the filler valve and close the access cover. Check the cylinder pressure according to Chan
3503 after the cylinder temperature stabilizes.
5. After detaching the service can, cap hose and fittings to prevent contamination.
6. Perform a leak check of the high pressure lines and clean off solution afterwards. If solution is not
properly cleaned off, unusual corrosion may result.
35-10-16
Page 35-17
Added: May 21, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUd.,L
a
PORTABLE OXYGEN SYSTEM.
REMOVAL OF OXYGEN C'NIT. (Refer to Figure 35-8.)
- WARNING -
Do not use grease or m y grease type fittings on any hardwon that
connects to the oxygen bottle or system hardware. When working
with the oxygen system make sure hands, clothing and tools arefree
oj oil, grease and dirt.
An oxygen unit can be released from its cradle by pulling down on the ring under the cradle. sliding the
unit forward. and lifting it out of the cradle.
-
INSPECTION AND OVERHAUL TIME.
Due to the nature of the process used to test compressed gas tanks, it is recommended that overhaul.
service or hydrostatic tests be conducted by an FAA or manufacturer (Scott Aviation) approved shop. The
following checks and charts give recommended inspection and overhaul times for the various parts of the
oxygen system.
-NOTE Oxygen cylinders are iifentmd by the ICC or DOT idcntfication
stamped on the cylinder. The standard weight cylinder (ICC or DOT
3AA1800) must be hydrostatic tested at the end o j each 5 year
period. Light weight cylinders (7CC or DOT 3HTJ8.W) must be
tested every 3 years and qfter 4380 rqfills, or IS years whichever
comesfirst, be replaced. The month andyear ojthe lost test stamped
on the cylinder beneath the ICC DOT idmtvication.
I. Inspect outlets. and using directions described in the next paragraph. check leaks both in the non-use
and use condition.
2. Check the pressure gauge for accuracy by removing the back section of the unit and connecting a
gauge of known accuracy, to the fill port.
3. lnspect tank for dents. bulges. major strap chafing marks or corrosion. Should any of these
conditions exist. the tank should be hydrostatically tested.
CHART 3504. OXYGEN SYSTEM COMPONENT LIMITS (PORTABLE)
Pans
lnspection
Overhaul
Regulator
Pressure Gauge
Outlets
Recharge Valve
Masks
300 Flight Hrs.
300 Flight Hrs.
300 Flight Hrs.
Each Use
Each Use
5 yrs.
5 yrs.
5 yrs.
Replace every 5 years
Replace as necessary
35-10-19
Page 35-18
Added: May 21, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
28 0s
1. OXYGEN BOllLES
2. MOUNTING BRACKET
3. FACE MASK
'\
Figure 35-8. Oxygen Installation (Portable)
TESTISG FOR LEAKS.
Apply detector fluid type CD- I solution or its equi\.alent. The solution should be shaken to obtain sud, or
foam. The suds or foam should be applied sparingl!. to the joints of a closed systern. Look for traces of bubble>.
S o \isible leakage should be found. Repair or replace any defective parts and retest s!,stem.
With the system pressuri7ed to senice pressure. further tests can be made. The rate of an!. leak should nor
exceed one percent of the total supply per 24 hour period. All traces of thedetector fluid should be H-ipedoft' at
the conclusion of the examination.
I. Check the c!.linder to be sure i t is securely mounted.
2. Check t he c!,linder for the ICC identification number and for the date of the last FAA inspect ion and
test.
3. If cylinder is completely empty it must be completely disassembled and inspected in an F A A or
manufacturer appro\.ed facilit!. before recharging.
4. Refer to FAA Manual AC 43.13-IA for more details.
35-10-21
Pant 35-19
Added: May i1. 1980
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
REMOVAL OF OI'TLETS.
I. Make sure control \alve is in full off position.
2. Connect a mask or connector t o the valve to release any pressure.
3. Using a suitable spanner w e n c h . remove the outlet.
4. The outlet can nou- be removed from the low pressure line.
IlVSTALLATlOh OF OL'TLETS.
I. Apply sealant (Permacel 412) t o the male end of the fitting.
2. Install the outlet t o the regulator extension with a suitable spanner wrench.
3. Torque the fittings into the outlets approximately 30 inch-pounds. D o not over torque as this could
damage the outlet.
PURGING OXYGEN SYSTEM.
The system should be purged whenever the cylinder pressure falls below 50 PSI o r if any lines are left open
for an! length of time. Also. if bottle is left a t below 200 PSI it mag develop odors from bacterial growth.
This u.ill make it necessary t o purge the system. Use the following procedures:
When performing this operation make sure the area is a No
Smoking Area, and is as clean as possible of oil and dirt.
I . Keep all doors and w i n d o w open.
2. Connect the oxygen recharging unit t o the filler valve.
3. Plug the oxygenmasks into the outlet valves and turn on the system.
4. Set the recharging unit pressure regulator t o deliver 50 psi and let the system purge for one hour. If
an!. odor is still present repeat the procedure for one o r more hours. If the odor persists after the second
purging. send the unit to its manufacturer. or a n approved shop.
CLEAKING OF FACE MASKS.
The disposable masks are designed for one-time use and require no maintenance. The pilot's and copilot's
masks can be cleaned a3 follows:
I . Remove the microphone from the mask.
2. Remove the sponge rubber discs from the masks turrtnts. D o not use soap to clean sponge rubber
discs. a s this would deteriorate the rubber and give off unpleasant odors. Clean in clean water and squeeze dr! .
3. Wash the rest of the mask with a very mild solution of soap and water.
4. Rinse the mask thoroughly to remove all traces of soap.
5 . Make sure the sides of the breathing bag d o not stick together while drying. as this may decrease the
life of the rubber in the bag. The mask can be sterilized with a solution of 70 percent ethyl alcohol.
- END 35-10-25
Page 35-20
Added: Ma!. 21. 1980
CHAPTER
VACUUM
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 31 VACUUM
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
GRID
NO.
EFFECTIVITY
GEYERAL
Description and Operation
Troubleshooting
DISTRIBUTION
Vacuum System Senice Tips
Vacuum Pump
Remo\.al of Vacuum Pump
Replacing Pump Fittings
lnstallation of Vacuum Pump
l'acuum Regulator Val\e
Adjustment of Vacuum Regulator Valve
Remo\,al and Replacement of Regulator Valve
ISDICATISG
Vacuum Gauge
Remo\al of Vacuum Sensor
lnstallation of Vacuum Sensor
37
- Cont./Effec.
Page - 1
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32.301 1301T
MAINTENANCE MANUAL
GENERAL.
The instrumentation in this airplane is designed to give a quick and actual indication of the attitude.
performance and condition of the airplane. Maintenance, other than described. shall be done by the
instrument manufacturer or an authorized repair station.
DESCRIPTION AND OPERATION.
The vacuum system employed to operate the gyro instruments is comprised. of an engine driven dry
vacuum pump. a vacuum regulator and filter. and necessary tubing to connect the components. A vacuum
gauge is used to constantly monitor the system.
TROUBLESHOOTING.
A Troubleshooting Chart is provided to assist in locating and correcting possible malfunctions in the
system.
CHART 3701. TROUBLESHOOTING (VACUUM SYSTEM)
1
Remedy
Cause
Trouble
Filter clogged or dirty.
Clean or replace filter.
Line from gyro to filter restricted.
Check line.
No vacuum gauge indication at instrument or
source.
Faulty gauge malfunctioning pump.
Replace gauge. Replace
Pump.
Low vacuum system
pressure.
Filter dirty.
Clean or replace filter.
Vacuum regulator valve incorrectly adjusted.
Adjust regulator valve in
accordance with Adjustments in this section.
Line from gyros to filter
restricted.
Repair or replace line.
Line from pump to gyros
leaking.
Check all lines and fittings.
h'o vacuum gauge indication at instrument.
37-OQO2
Page 37-01
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
CHART 3701. TROUBLESHOOTING (VACUUM SYSTEM) (cont)
Cause
Remedy
hiormal pressure indication but sluggish operation
of instruments.
Faulty instrument.
Replace instrument.
High system pressure.
Vacuum regulator incorrectly adjusted.
Adjust regulator.
Vacuum regulator sticking
or dirty screen.
Clean and check operation
of regulator.
Lines leaking.
Check lines and fittings.
Vacuum pump malfunctioning.
Replace pump.
Vacuum pump malfunctioning.
Replace pump
Regulator sticky.
Clean regulator.
Regulator sticky.
Clean regulator.
Oil in pump due to leaky
engine seal or cleaning fluid
blown into pump while
cleaning engine.
Replace pump
Leak in system.
Repair or replace lines.
Worn pump.
Replace pump.
Stuck regulator.
Clean or replace regulator.
Trouble
Regulator cannot be adjusted to produce correct
pressure.
Vacuum correct on ground
but will not maintain pressure at altitude.
Vacuum correct but pilot
reports pressure erratlc or
shoals complete loss in
flight.
Pressure can only be m a ~ n tained at full throttle on
ground.
37-OG02
Page 32-02
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
DISTRIBUTION.
V A C U U M SYSTEM SERVICE TIPS.
The following information is intended to acquaint field service personnel with a means to diagnose
vacuum system service symptoms on those components which arc serviced by removal and replacement. These
items include hoses, clamps, gyro filters, vacuum regulating valves and vacuum gauges.
I. Hoses and Clamps:
A. These items should be examined periodically and inspected carefully whenever engine
maintenance activities cause hose disconnections to be made at the pump, regulating valve, gyros and or
vacuum gauge.
B. The ends of the hoses should be examined for rubber separation and slivers of rubber on the
inside diameter of the hoses. These slivers can and d o become detached. If this happens. the vacuum pump
suck these loose particles and eventually ingest them. This can cause premature pump service.
C. Hose clamps and fittings should be replaced when broken, damaged or corroded.
- CAUTION When replacing any of the threadedfittings, DO NOT USE PIPE
DOPE or any other anti-seize 1or compound. TheAIRBORNE
fittings are all c a h i u m plated to avoid h e need for any other
antiseize materials. The reason for this caution is to protect the
pump from ingesting any foreign materials that could cause
premature service. Although 3M-45 x I/, t d b n pipe thread sealant
tape is used on PA-32-301T serial number 324029001 and up.
Insure that 1 to 2 lead-in threads are free of sealant tape.
2. Vacuum Gauges:
A. Vacuum gauges seldom require service and usually are replaced when malfunctions occur.
-- NOTE
-
Vacuum gauge failure in a properly operating vacuum system does
not impair sqfcry of flight.
B. If the vacuum gauge malfunctions in a manner to cause an incorrect reading in normal cruise
conditions, the gauge must be checked by comparing the reading with a gauge of known accuracy. If the gauge
is indicating correct values and the system vacuum level is not in accordance with the specified vacuum. then
and only then should the regulator be reset.
C. Visual examination of the gauge performance should cover the following steps:
(1) With engine stopped and no vacuum applied to the gauge, its pointer should rest against the
internal stop in the 9 o'clock position. Any other displacement from this position suggests
need for replacement.
(2) A slight overshoot during engine startup, not to exceed half an inch (1 12")of mercury. is
normal and is not cause to replace gauge.
With engine operating at normal cruise RPM,the gauge should read from 4.8 inches to 5.2
3
inches of mercury (vacuum).
(4) At 1200 RPM,the vacuum gauge reading should be more than four inches of mercurj.
37- 10-01
Page 37-03
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
3. Gyro Filters:
A. Gyro filters must be serviced on a scheduled basis, not to exceed 100 hours, or sooner as
condition indicates.
B. The system installation employs a large central filter and differential vacuum gauge that
continuously monitors the filter condition while indicating vacuum readings.
The latest systems which employ a centralfilter in combination with
a differential vacuum gauge will indicate a decline in panel gauge
reading when thefilter becomes clogged and vocuum declines be10 w
the recommended value. Thefilters should be replaced when gauge
reading declines below the recommended value; do not adjust
regulator.
4.
Vacuum Regulator:
A. The vacuum regulating valve seldom needs replacement. Symptoms that suggest replacement
are:
( I ) Chatter as indicated by rapid fluctuation of the vacuum gauge needle or an audible sound.
(2) Non-repeatability of the vacuum gauge reading when the panel gauge is not suspect or has
been checked against a known test gauge (cruise RPM only).
B. All modes of regulator malfunction tend to increase the vacuum power applied to the gyros.
Thus. although excess vacuum is applied. a loss of vacuum does not occur.
C. The gyros themselves act as a limiting device to keep the vacuum power applied from exceeding
safe levels.
If the panel gauge has been checked andfound OK and the vacuum
gauge reading does not repeat within the range of 4.8 t o 5.2 inches of
mercury, then the regulating valve should be changed. Observe the
usual precautions for maintaining system cleanliness t o avoid
premature pump service.
VACUUM PUMP.
The vacuum pump is of the rotary vane, positive displacement type. This unit consists essentially of an
aluminum housing in which a rotor, with moving blades is incorporated. This assembly is driven by means of a
shear type coupling mated to the engine driven gear assembly. This coupling is designed to separate. should an
internal problem occur in the pump, so as to protect the engine and accessory drive gears. The pump is
mounted on the accessory section of the engine.
37-10-02
Page 37-04
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
REMOVAL OF VACUUM PUMP.
1.
Remove the top portion of the engine cowling. (Refer to Chapter 71 .)
2. Loosen the hose clamp and remove the hose from the pump fitting.
3. Remove the four retaining nuts, lock washers and plain washers used to secure the pump to the
engine; then remove the pump.
REPLACING PUMP FITTINGS.
1. Before installing any fittings on the pump, check for any external damage. A pump that has been
damaged or dropped should not be installed.
2. When a vise is used to hold the pump while installing fittings, suitable caution must be exercised to
avoid pump damage. The square mounting flange must be held between soft wood blocks and only at right
angles to the vise jaws. Use only enough vise pressure to hold the pump firmly.
- CAUTION DO NOT apply vise pressure to the outside dicrmeta or overall
length of the pump.
3. The ports of the AIRBORNE pump have been treated withadry filmlubricant and the AIRBORSE
fittings are cadmium plated thus eliminating any need for thread lubricants. If thread lubricant is required. use
a powdered moly-sulfide or graphite in dry form or in a n evaporating vehicle; or employ a silicone spray.
Apply sparingly to external threads of fittings only.
- CAUTION DO NOT use pipe tape, thread dope, hydrocarbon oil or grease, as
these can contaminate the pump and cause ma@imetion.A hhough
3M-48 x % tcjlon pipe thread sealant tapt is used on PA-32-301T
serial number 32-8029001 and up. Insure that 1to 2 lead-in threads
are free o j sealant tape.
4.
5.
With the pump properly secured in the vise, insert fittings in ports and hand tighten firmly.
Using a wrench, tighten each fitting from one-half to two additional turns.
INSTALLATION O F VACUUM PUMP.
1. Place the pump gasket in its proper place and align the spline on the pump drive with the spline on the
engine drive assembly.
-- CAUTION
-
The only pump mounting gasket authorized and qpprovedfor use
on the A irborne vacuumpump is the Airborne gasket 83-1-2,Piper
part number 7751 8.59. Use of any other gasket may resuh in oil
seepage or leakage at the mounting surface.
37-10-05
Pane 37-05
Revised: Stptem ber i 3 , 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAiNTENANCE MANUAL
2. Secure the pump to the engine with four plain washers, lock washers and retaining nuts. Torque the
nuts 50 t o 10 inch-pounds.
3. Connect the hoses to the pump and secure with hose clamps.
4. Reinstall the engine cowling.
VACUUM RECULATOR VALVE.
One vacuum regulator valve is incorporated in the system t o control vacuum pressure to the gyro
instruments. The regulator valve is located under the instrument panel. Access t o the valve for maintenance
and adjustment is gained from below the instrument panel.
ADJUSTMENT OF VACUUM REGULATOR VALVE.
I. Loosen the locking nut or lock tab o r remove the protective cap from the valve. depending on-which
type is installed.
-- NOTE
-
Do not attempt adjustment o j this valve with the engine in
operation, without a qualified pilot or other responsible person at
the controls.
2. Start the engine, after allowing time for warm-up, run the engine a t medium RPM.
3. With the engine running at medium RPM.the suction gauge should indicate 5.0 inches of mercury 2.2
inches of mercury. If the pressure reading fails t o fall within this range. shut down the engine and adjust the
regulator valve by moving the valve adjustment screw clockwise t o increase the pressure. and counterclockwise
t o decrease the pressure. Start the engine and repeat the check. With engine running at medium RPM. the
suction gauge should indicate 5.0 inches of mercuryi.2inches of mercury. If the airplane is not equipped with a
suction gauge. it will be necessary to connect a gauge by removing the plug from the back of the artificial
horizon. and attaching a temporary gauge.
4. Restart the engine and repeat the check.
5. After the system pressure has been adjusted to these recommended settings, remove the gauge and
install the plug. replace the protective cap o r retighten the locknut o r lock the lock tabs, whichever applles to
the type of valve installed.
REMOVAL A N D REPLACEMENT OF RECULATOR VALVE.
I . T o remove the regulator valve, disconnect the three vacuum lines and disconnect the wires from the
pressure switch. Remove the mounting nut. Remove the valve from the airplane.
2. Replace regulator in reverse order given for removal. Check complete vacuum system for proper
operation.
37-10-08
Page 37-06
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
VACUUM GAUGE.
The suction gauge is mounted in the right side of the instrument panel. This gauge is calibrated in inches of
mercury and indicates the amount of vacuum created by the engine driven vacuum pump. The suction gauge
has a direct pressure line and vent line. Therefore. these aircraft indicate the differential pressure or actual
pressure being applied to the gyro instruments. As the system filter becomes clogged or lines obstructed. the
gauge will show a decrease in pressure. D o not reset the regulator until the filter and lines have been checked.
REMOVAL OF VACUUM SENSOR.
Access t o the sensor unit is gained by reaching up under the instrument panel to the vacuum regulator.
Removal is accomplished by the following:
1. Disconnect the two electrical leads.
2. Unscrew the sensor unit from the vacuum regulator.
3. Cover hole to prevent foreign matter from entering regulator.
INSTALLATION OF VACUUM SENSOR.
1. Screw sensor unit into vacuum regulator.
2. Reconnect the two electrical leads.
3. Perform operational check.
-- END
-
Page 37-07
Issued: January 2, 1980
-
PIPER AIRCRAFT
PA-32-301 /301 T
MAIXTENANCE MAS1'AL
CHAPTER
ELECTRICAL
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE hl ANUAL
CHAPTER 39 - ELECTRICAL PANELS. PARTS A N D INSTRL'MEIVTS
TABLE OF CONTENTSjEFFECTIVlTY
CHAPTER
SECTIOY
SL'BJECT
39-40-00
39-4 1-00
39-4 1-0 1
SUBJECT
GRID
NO.
EFFECTIi'ITl'
ML'LTIPURPOSE ELECTRICAL PARTS
Electrical Switches and Circuit Breakers
Remo~alof Electrical Switches
Refer to Chapter 91 for a11 wiring diagrams (schematics).
-
39 Cont./Effec.
-
Page 1
Revised: August 1 1. 1983
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
MVLTIPC'RPOSE ELECTRICAL PARTS.
I
ELECTRICAL SWITCHES A N D CIRCL'IT BREAKERS.
The switches are of the rocker type. The switches are mounted on the forward left side panel. The circuit
breakers are single hole mounting. pushbutton type with manual reset. They are on a circuit breaker panel on
the lower right hand corner of the instrument panel.
REMOI'AL OF ELECTRICAL SWITCHES.
I . T o galn access to the electrical suitches. refer to Chapter 33. Remo\al of Suitch Panel 4\sembl!
e screu below the s u ~ t c hon rhc. Iron1 111
2. For a particular sultch remo\al. remobe the screu a b o ~ and
the snitch panel.
3. From behind the switch panel remo\e the switch. and disconnect the electrical connections
-- NOTE
-
Make note of the placement of the electrical leads to facilitate
reinstallation.
Page 39-01
Revised: May 21, 1980
CHAPTER
STRUCTURES
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
CHAPTER 51 STRUCTURES
TABLE OF CONTENTS/EFFECTIVITY
CH.APTER
SECTIO\
SUBJECT
SUBJECT
GRID
S0 .
EFFECTI\'ITI
GESERAL
Description
STRUCTURAL REPAIRS
Fiberglass Repairs
F~berglassTouch-L'p and Surface Repairs
Fiberglass Fracture and Patch Repairs
Thermoplastic Repairs
Sal'et! b'alk Repair
Surface Preparation
Product Listing for Liquid Safet! Walk Compound
Application of Liquid Safely Walk Compound
Surface Preparation for Pressure Sensitive Safety M'alk
.4pplication of Pressure Sensiti\-e Safety Walk
2F 19
2F 19
2F20
2 FZO
2 F23
ZG7
2G7
I R K-84
l R 8-81
1 R 844
I R b-84
ZG 7
2G 7
2G8
2G8
51
- Cont./Effec.
Page - 1
Revised: August 9. 198.1
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
DESCRIPTION.
T h e PA-32-30! 301T are all metal semi-monocoque structures. T h e fuselages are constructed of
bulkheads. stringers and stiffeners. t o which all o f the outer skin is riveted. There are two cabin entr!. doors:
one o n the right side of the fuselage above the wing and the other o n the left side of the fuselage aft of the wing
trailing edge. A baggage door is provided aft of the firewall on the right side of the fuselage and a cargo door
adjoins the rear cabin door. T h e w i n g and empennage a r e all metal. full cantilever semi-monocoque t>pe
construction with remo\,able tips.
STRIrCTG'RAL REPAIRS.
Structural repair methods used must be made in accordance with the regulations set forth in F.41
Ad\.ison. Circular 43-13-1.4. T o assist in making repairs a n d o r replacements. Figure 5 1-1 identifies the t! pt:
and thickne4s of \.arious skin material used.
- WARNING -
No access holes are permitted in any corurol surjaces. The use of
patch plates for repairs of all movable tailurrjaces isprohibited. The
use o j any filler maferial normally used for repair oj minor dents
and/or materials used for filling the inside of surjaces is also
prohibired on a11 movable tail surfaces.
Sever make a skin replacement or patch plate from material other than the type of the original skin. or ol'a
different thickness than the original skin. The repair must be as strong as the original skin. H owel er. flexibilit!
must be retained s o the surrounding areas will not receive extra stress.
I
I
FIBERGLASS REPAIRS.
T h e repair procedure in this manual will describe the methods for repair of Fiberglass Re~nforced
Structures. Fiberglass Touch-Up and Surface Repairs such as blisters. open seams. delamination. ca\ it~cc.
small holes and minor damages that havc not harmed the fiberglass cloth material. Fiberglass Fracturc and
Patch Repairs a s puncture. breaks and holes that have penetrated through the structure and damaged rhe
fiberglass cloth. A repair kit. part number 756 729 will furnish necessary material for such repairs. and 1s
available through P ~ p e rAircraft Dealers.
Very carejulCy follow resin and catalyst mixing instructions
furnished wah repair kit.
51-10-01
Page 51-01
Revised: ~ u ~ u s t - 91984
.
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
I
FIBERGLASS TOLCH-UP AND SURFACE REPAIRS.
I . Remo\e wan. oil and dirt from around the damaged area with acetone. Meth!.leth!.lketone or
equkalent and remoie paint t o gel coat.
2. The damaged area may be scraped with a fine blade knife o r a power drill with a burr attachment to
roughen the bottom and sides of the damaged area. Feather the edge surrounding t he scratch o r ca\ it!.. Do not
undercut the edge. ( I f the scratch or ca\ ity is shallow and penetrates only thesurface coat; continue to Step 8 . )
3. Pour a small amount of resin into a jar lid or o n a piece of cardboard. just enough t o fill the area being
( worked on. Mix an equal amount of milled fiberglass with the resin. using a putty knifeor stick. Add catalyst.
according t o kit instruction. to the resin and mix thoroughly. A hypodermic needle may be used to inject gel
1 into small ca\ities not requiring fiberglass millings mixed with the gel.
4 . Work the mixture of resin. fibers and catalyst into the damaged area. using thesharp point of a putt!
knife o r stick t o press it into the bottom of the hole and t o puncture any air bubbles which ma! be present. Fill
the scratch o r hole abo\.e the surrounding undamaged area about 1 , I 6 inch.
5. La!. a piece of cellophane o r waxed paper over the repair t o cut off air and start the cure of gel
mixture.
6 . Allow the gel to cure 10 to I5 minutes until it feels rubbery t o the touch. Remo1.e the cellophane and
trim flush with the surface. using a sharp razor blade o r knife. Replace the cellophane and allou t o curs
completel!. for 30 minutes t o an hour. T h e patch will shrink slightly below the structure surface as it cures. ( I f
\tax paper is used. ascertain %.ax is remo\,ed from surface.)
7 . Rough up the bottom and edges of the hole with the electric burr attachment or rough sandpaper.
Feather hole into surrounding gel coat. d o not undercut.
8 . Pour out a small amount of resin. add catalyst and mix thoroughly. using a cutting motion rather
than stirring. l ' s e no fibers.
9. Using the tip of a putty knife or fingenips. fill the hole t o about 1 16 inch a b o \ e the surrounding
surface with the gel coat mixture.
10. La!. a piece of cellophane o\.er the patch to start the curing process. Repeat Step 6. trimming patch
when partiall!, cured.
I I . After trimming the patch. immediately place another small amount of gel coat on cut edge of the
patch and co\.er w.ith cellophane. Then. using a squeegee o r the back of a razor blade. squeegee lei el with arc3
surrounding the patch. lea\e the cellophane on patch for one o r two hours o r overnight. for complete cure.
I?. After repair has cured for 24 hours. sand the patched area using a sanding block with fine wet
sandpaper. Finish by priming. again sanding and applying color coat.
I
FIBERGLASS FRACTURE A N D PATCH REPAIRS.
I.
Remo\.e wax. oil and dirt from around damaged area with acetone. methylethylketone or equi\ alent.
2. Using a key hole saw. electric saber saw. or sharp knife cut away ragged edges. Cut back t o sound
material.
3. Remo\e paint three inches back from around damaged area.
4 . Working inside the structure. bevel the edges t o approximately a 30 degree angle and rough-sand t hc
hole and rhe area around it. using 80-grit dry paper. Feather back for about two inches all around the hole.
This roughens the surface for strong bond with patch.
51-10-03
Page 51 -02
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
Figure 51-1. Skin Material and Thickness
51-10-03
Page 51-03
Issued: Januarj 2. 1980
PIPER AIRCRAFT
PA-32-30! /301T
hlAIh'TESANCE MAh'l'AL
1
MATERIAL
NUIBER
THICKNES
I
B l 3
(11
m-T3
m-T3
-7'3
msT3
NOTE:
B t 3
=(2)
FIDERGUS
=l3
If)
THERNOPMC
OR FIBER(2l
==
-*
m-7'3
If)
LEFT WING SHOWN. RIGHT WING
OP#)SITE.
1. HEAT TREAT TO 2024142 AFTER
FORMING.
2. HEAT TREAT TO 2024-T3 AFTER
FORMING.
3. PA-32-301 S/N 32-.
AND
UP. AND PA-32-301T S/N 8024004
AND UP.
5052.~34
Figure 51-1. Skin \l.~tcrial and Thickness (cont)
51-1093
Page 51-04
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
5. Cover a piece of cardboard or metal with cellophane. Tape it to the outside of the structure covering
the hole completelv. The cellophane should face toward the inside of the structure. If the repair is on a sharp
contour or shapedearea. a sheet of aluminum formed to a similar contour may be placed over the area. The
aluminum should also be covered with cellophane.
6. Prepare a patch of fiberglass mat and cloth to cover a n area two inches larger than the hole.
7. Mix a small amount of resin and catalyst. enough t o be used for one step at a time. according to kit
instructions.
8. Thoroughly wet mat and cloth with catalyzed resin. Daub resin on mat first. and then on cloth. Mat
should be applied against structures surface with cloth on top. Both pieces may be wet out on cellophane and
I applied a s a sandwich. Enough fiberglass cloth and mat reinforcements should be used to at least replace the
amount of reinforcements removed in order t o maintain the original strength. If damage occurred as a stress
crack. a n extra layer or two of cloth may be used to strengthen area.
9. Lay patch over hole on inside of structure, cover with cellophane, and squeegee from center to edges
to remove all air bubbles and assure adhesion around edge of hole. Air bubbles will show white in the patch
and they should all be worked out to the edge. Remove excess resin before it gels on the part. Allow. patch 10
cure completely.
10. Remove cardboard or aluminum sheet from outside of hole and rough-sand the patch and edge of
hole. Feather edge of hole about two inches into undamaged a n a .
I I . Mask area around hole with tape and paper to protect surface. Cut a piece of fiberglass mat about one
inch larger than the hole and one or more pieces of fiberglass cloth two inches larger than the hole. Brush
catalyzed resin over hole, lay mat over hole and wet out withcatalyzed resin. Use a daubing action with brush.
) Then apply additional layer or layers of fiberglass cloth to build up patch to the surface of structure. U'er out
each layer thoroughly with resin.
It. With a squeegee or broad knife. work out all air bubbles in the patch. Work from center to edge.
pressing patch firmly against the structure. Allow patch to cure for I5 t o 20 minutes.
13. As soon as the patch begins to set up. but while still rubbery. take a sharp knife and cut awa! extra
cloth and mat. Cut an outside edge of feathering. Strip cut edges of structure. Do this before cure iscomplete.
to save extra sanding. Allow patch to cure overnight.
14. Using dry 80-grit sandpaper on a power sander or sanding block, smooth patch and blend with
surrounding surface. Should air pockets appear while sanding. puncture and fill with catalyzed resin. A
hypodermic needle may be used to fill cavities. Let cure and resand.
IS. Mix catalyzed resin and work into patch with fingers. Smooth carefully and work into any crevices.
16. Cover with cellophane and squeegee smooth. Allow to cure completely before removing cellophane.
Let cure and resand.
17. Brush or spray a coat of catalyzed resin to seal patch. Sand patch, finish by priming. again sanding
and applying color coat.
1
I
- NOTE -
Brush and hands may be ckaned in solvents such as acetone or
methylethylketone. Ijsolvenrs a n nor avaikbk, a strong solution of
detergent and water may be used.
THERMOPLASTIC REPAIRS.
The following procedure will assist in making field repairs to items made of thermoplastic which are used
throughout the airplane. A list of material needed t o perform these repairs is given along with suggested
suppliers of the material. Common safety precautions should be observed when handling some o f t he mate ria Is
and tools used while making these repairs.
51-10-04
Page 51-05
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 5101. LIST OF M A T E R I A & (THERMOPLASTIC REPAIR)
DESCRIPTIONS
ITEMS
Buff~ngand Rubbing
Compounds
-
Automot~veType DuPont
#7
SUPPLIERS
Du Pont Company
Wilmington. Del. 19898
Ram Chemical #69 x I
Ram Chemicals
Gardena. Cal. 90248
M~rrorGlaze #I
Mirror Bright Polish Co.. Inc.
Irvin. Cal. 92713
Cleaners
Fantastic Spray
Perchloretylene
VM&P Naphtha (Lighter
Fluid)
Obtain From Local Suppl~crs
ABS-Solbent Cements
Solarite # I I Series
Solar Compounds Corp.
Linden. N.J. 07036
Sol\en~s
Methylethylketone
Methylene Chloride
Acetone
Obtain From Local Suppliers
Epox! Patchlng
Compound
Solarite #400
Solar Compounds Corp.
Linden. N.J. 07036
Hot Melt Adhesives
Polyamids and Hot Melt
Gun
Stick Form I 2 in. dia.
3 in. long
Sears Roebuck & Co. or Most
Hardware Stores
Hot Air Gun
Temp. Range 300" to
400" F
Local Suppl~ers
51-10-04
Page 51-06
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
I.
I
Surface Preparation:
A. Surface dirt and paint if applied must be removed from the item being repaired. Household
cleaners have proven most effective in removing surface dirt.
B. Preliminary cleaning of the damaged area with perchlorethylene or V M & P Naphtha will
generall~insure a good bond between epoxy compounds and thermoplastic.
2. Surface Scratches. Abrasion or Ground-in-Din: (Refer to Figure 51-2.)
A. Shallow scratches and abraded surfaces are usually repaired by following directions on
containers of conventional automotive buffing and rubbing compounds.
B. If large dirt particles are embedded in thermoplastic parts. they can be removed with a hot air
gun capable of supplying heat in the temperature range of 300" to 400°F. Use care not to overheat the material.
Hold the nozzle of the gun about 1 4 of an inch away from the surface and apply heat with a circular motion
until the area is sufficiently soft to remove the dirt panicles.
C. The thermoplastic will return to its original shape upon cooling.
3. Deep Scratches. Shallow Nicks and Small Holes: (Less than I inch in diameter.) (Refer to Figure
5 1-3.)
A. Solvent cements will fit virtually any of these applications. If the area to be repaired is very small.
it may be quicker to make a satisfactory cement by dissolving thermoplastic material of the same type being
repaired in solvent until the desired paste-like consistency is achieved.
B. This mixture is then applied to the damaged area. Upon solvent evaporation. the hard durable
solids remaining can easily be shaped to the desired contour by filing or sanding.
C. Solvent adhesives are not recommended for highly stressed areas. on thin walled parts or for
patching holes greater than 1 4 inch in diameter.
Figure 5 1-2. Surface Scratches. Abrasions or Ground-in-Dirt
51-10-04
Page 51-07
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-31 /301T
MAINTENANCE MANUAL
Figure 51-3. Deep Scratches. Shallow Kicks and Small Holes
825
THOROUGHLY MIX
USING FIGURE EIGHT
Figure 51-4. Mixing of Epoxy Patching Compound
L
D. For larger damages an epoxy patching compound is recommended. This type material is a two
part, fast curing. easy sanding commercially available compound.
E. Adhesion can be increased by roughing th'e bonding surface with sandpaper and by utilizing as
much surface area for the bond as possible.
F. The patching compound is mixed in equal portions on a hard flat surface using a figure eight
motion. The damaged area is cleaned with perchlorethylene o r VM&P Naphtha prior to applying the
compound. (Refer to Figure 51-4.)
G. A mechanical sander can be used after the compound is cured. providing the sander is kept in
constant motion t o prevent heat buildup.
51-10-04
Page 51-08
Revised: August 9, 1984
PIPER .AIRCRAFT
P.4-32-301/301
T
>I.4ISTENAT\'CE 31ASI'AL
Figure 5 1-5. M'elding Repair Method
827
DOUBLER P U T E BONDED TO
UNDERSIDE OF DAMAGED AREA
I
I
HOLES
Figure 5 1-6. Repairing of Cracks
51-lo-04
Page 21-ll9
Issued: Januar! 2. 1980
PIPER .AIRCR.AFT
PA-32-301 /301 T
Jl.4lSTES.4SCE 3 4 . 4 S l . . A L
INC
UND
DAMAGED AREA
I
Figure 51-7. l ' a r i o ~Repair.
~~
51- 10-IIJ
Page 21-10
Issued: Januar! 2. I9XO
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
H. For repairs in areas involving little or no shear stress. the hot melt adhesives. polyamids which
are supplied in stick form may be used. This type of repair has a low cohesive strength factor.
I . For repairs in areas in\.olving small holes. indentations or cracks in the material where high
stress is apparent or thin walled sections are used. the welding method is suggested.
J . This welding method requires a hot air gun and ABS rods. T o weld. the gun should be held to
direct the flow of hot air into the fusion (repair) zone. heating the damaged area and rod simultaneousl>..The
gun should be moved continuously in a fanning motion to prevent discoloration of the material. Pressure must
be maintained on the rod to insure good adhesion. (Refer t o Figure 51-5.)
K . After the repair is completed. sanding is allowed to obtain a surface finish of acceptable
appearance.
4. Cracks: (Refer to Figure 51-6.)
A. Before repairing a crack in the thermoplastic pan. first determine what caused the crack and
alleviate that condition to prevent it recurring after the repair is made.
B. Drill small stop holes at each end of the crack.
C. If possible. a double plate should be bonded to the reverse side of the crack to provide extra
strength to the part.
D. The crack should be "V" grooved and filled with repair material. such as solvent cement. hot
melt adhesive. epoxy patching compound or hot air welded. whichever is preferred.
E. After the repair has cured. it m a y b e sanded to match the surrounding finish.
5 Repairing Major Damage: (Larger than I inch in diameter.) (Refer to Figure 51-7.)
A. If possible a patch should be made of the same material and cut slightly larger than the section
being repaired.
B. When appearances are important. large holes. cracks. tears. etc.. should be repaired b! cutting
out the damaged area and replacing it with a piece of similar material.
C. N'hen cutting away the damaged area. under cut the perimeter and maintain a smooth edge. The
patch and or plug should also ha\.e a smooth edge to insure a good fit.
D. Coat the patch with solvent adhesive and firmly attach it over the damaged area.
E. Let the patch dry for approximately one hour before any additional work is performed.
F. The hole. etc.. is then filled with the repair material. A slight overfilling of the repair material is
suggested to allow for sanding and finishing after the repair has cured. If patchingcompound is used the repair
should be made in layers. not exceeding a I 2 inch in thickness at a time. thus allowing the compound to cure
and insuring a good solid buildup of successive layers as required.
6. Stress Lines: (Refer to Figure 51-8.)
A. Stress lines produce a whitened appearance in a localized area and generally emanate from the
se\,ere bending or impacting of the material. (Refer to Figure 51-9.)
B. T o restore the material to its original condition and color. use a hot air gun or similar heating
de\.ice and carefull\- apply heat to the affected area. D o not overheat the material.
7. Painting the Repair:
A. An important factor in obtaining a quality paint finish is the proper preparation of the repair
and surrounding area before applying any paint.
B. I t is recommended that parts be cleaned prior to painting witha commercial cleaner or a solution
made from one-fourth cup of detergent mixed with one gallon of water.
C. The paint used for coating thermoplastic can be either lacquers or enamels depending on which
is preferred by the repair facility or customer. (See XOTE.)
It is extremely important that solvent formulolions be considered
when selecting a point, because not all lacquers or enamels can be
used satisfactorily on thermoplastics. Some solvents used in the
paints can sign if cant!^ affect and degrade the plastic properties.
51-10-04
Page 51-11
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAISTESANCE MANUAL
*
827
STRESS
d
Figure 51-8. Repair of Stress Lines
1
829
--.-----
PROFILE VIEW INDICATING
DAMAGED A R U
Figure 51-9. Repair of Impacted Damage
51-10-04
Page 51-12
Issued: Januar!. 2. 1980
PIPER AIRCRAFT
PA-32301/301T
MAINTENANCE MANUAL
D. Another important matter to consider is that hard. brittle coatings that are usually best for
abrasion resistance should not be used in areas which incur high stress. flexing or impact. Such coating may
crack, thus creating a weak area.
SAFETY WALK REPAIR.
SURFACE PREPARATION.
1. Clean all surfaces with a suitable cleaning solvent to remove dirt, grease and oils. Solvents may be
applied by dipping. spraying or mopping.
2. Insure that no moisture remains on the surface by wiping with a clean dry cloth.
3. Outline the area to which the liquid safety walk compound is to be applied. and mask adjacent
surfaces.
-- NOTE
-
Newly painted surf4ces shall be allowed to dry jor 2.5 hours
minimum prior to the application of the sajety walk.
PRODUCT LISTING FOR LIQUID SAFETY WALK COMPOUND.
1. Suggested Solvents:
Safety Solvent per MIL-S-187 18
Sherwin Williams Lacquer Thinner R7KC 120
Glidden Thinner KO. 207
2. Safety Walk Material:
Walkway Compound and Matting Nonslip (included in Piper P a n KO. 179872)
APPLICATION OF LIQUID SAFETY WALK COMPOUND.
Liquid safety walk compound shall be applied in an area, free of moisture for a period of 24 hours
minimum after application. Do not apply when surface to be coated is below 50° F. Apply liquid safety walk
compound as follows:
I. Mix and thin the liquid safety walk compound in accordance with the manufacturer's instructions on
the container.
2. Coat the specified surfaces with a smooth. unbroken film of the liquid safety walk compound. A nap
type roller or a stiff bristle brush is recommended, using fore and aft strokes.
3. Allow the coating to dry for I5 minutes to one hour before recoating or touch-up; if required after
application of the initial coating.
4. After recoating or touch-up, if done, allow the coating to dry for I5 minutes to one hour before
removing masking.
The coated surf4ce shaU not be waked on jor six hours minimum
after application of final coating.
Page 51-13
Issued: January 2, 1980
PIPER AIRCRAFT
PA-3>301/301T
MAINTENANCE MANUAL
SURFACE PREPARATION FOR PRESSURE SENSITIVE SAFETY WALK.
The areas to which the pressure sensitive safety walk is to be installed must be free from all contaminates
and no moisture present. If liquid safety walk is installed the area must be prepared as follows:
I . Area must be masked off to protect painted surfaces.
2. Apply suitable stripper MEK Federal Spec. TT-M-261,U.S. Rubber No. 3339 to wingwalk
compound. As compound softens remove by using putty knife or other suitable tool.
3. Area must be clean and dry prior to painting.
4. Prime and paint area.
.
-
NOTE
-
Newty painted suflaces shall be allowed to dry for 2.5 hours
minimum prior to the application of the sojety walk.
APPLICATION OF PRESSURE SENSITIVE SAFETY WALK.
Wipe area with a clean dry cloth to insure that no moisture remains on surface. Do not apply when surface
temperature is below 50°F. Apply pressure sensitive safety walk as follows:
1. Peel back the full width of the protective liner approximately 2 inches from the leading edge of the
safety walk.
2. Apply the safety walk to the wing area. begin at the leading edge. insure proper alignment and
position from wing lap.
3. Remove the remaining protective liner as the safety walk is being applied from front to back of wing
area.
4. Roll firmly uith a long handled cylindrical brush in both lengthwise directions. Make sure all edges
adhere to the wing skin.
5 . Install and rivet leading edge retainer.
- END -
51-10-10
Page 51-14
Issued: January 2, 1980
I
I
a
CHAPTER
DOORS
PIPER AIRCRAFT
PA-32-30
1/30 1T
MAINTENANCE M A N U A L
-
CHAPTER 52 DOORS
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIO\
SL BJECT
SUBJECT
GRID
3 0.
EFFECTIVIT).
GESERAL
PASSENGER 'CREW
Forward Aft Cabin Door
Remo\.al of Door
lnstallation of Door
Adjustment of Door
Door Latch Mechanism
Removal of Door Latch Mechanism
lnstallation of Door Latch Mechanism
Adjustment of Door Latch Mechanism
Door Lock Assembly
Remoial of Door Lock Assembly
lnstallation of Door Lock Assembly
Door Safety (Auxiliary) Latch
Remobal of Door Safety (Auxiliary) Latch
lnstallation of Door Safety, (Auxiliary) latch
Adjustment of Door Safety (Auxiliary) latch
Door Snubber
Remobal and lnstallation of Door Snubbers
CARGO
Baggage Door
Remo\ al of Baggage Door
lnstallat~onof Baggage Door
Baggage Door Lock Assembly
Remo\al of Baggage Door Lock Assembly
lnstallation of Baggage Door Lock Assembly
Baggage Door Hinge
Removal of Baggage Door Hinge
lnstallation of Baggage Door Hinge
52
- Cont./Effec.
Page - 1
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
GENERAL.
This airplane has one entrance door located on the right side of the fuselage and a passenger compartment
and baggage door aft of the left wing trailing edge. A forward baggage door is provided on the right side of the
fuselage. forward of the cabin entrance door.
I
FORWARDIAFTCABINDOOR.
REMOVAL OF DOOR.
I.
2.
3.
Remove the clevis bolt. washer and bushing from the door holder assembly.
Remove cotter pins. clevis pins and washers from door hinges.
Remove the door from the airplane.
INSTALLATION O F DOOR.
1.
lnsen the door into position and install the washers, clevis pins and cotter pins on the door hinges.
2. For adjustment of door. refer to Adjustment of Door.
3. Hook up and install the clevis bolt, bushing and washer into the door holder assembl!.
ADJUSTMENT O F DOOR.
I . To acquire the proper venical adjustment of the door. insert the necessary washer combination
between the cabin door hinge and fuselage bracket assembly.
2. Additional adjustments may be made by tapping out the door hinge bushings and rotating them to
obtain the hinge centerline location that will provide proper door fit.
3. To insure long life of door seals and improve scaling characteristics. it is recommended they be
lubricated with a fluorocarbon or similar dry lubricant in a spray can.
I
DOOR LATCH MECHANISM.
REMOVAL OF DOOR LATCH MECHANISM.
I. Remove the door latch mechanism by removing the door trim upholstery and the screws that attach
the latch plate and latch mechanism t o the door.
2. Disconnect the latch pull rod from the inside door handle.
3. Remove the complete latch mechanism.
INSTALLATION OF DOOR LATCH MECHANISM.
I . Place the latch assembly into position on the door.
2. Connect the latch pull rod to the inside door handle.
52-10-07
Page 52-01
Revised: ~ u ~ u s t - 91984
,
'
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
3 Replace the screus that attach the latch plate and mechanism t o the door. Install the door
upholster! and secure u i t h screus.
trim
ADJUSTMENT OF DOOR LATCH MECHANISM.
.To adjust the door latch. loosen the screws on the striker plate. make necessary adjustment. and retighten
the screus.
I
DOOR LOCK ASSEMBLY.
REMOVAL OF DOOR LOCK ASSEMBLY.
I.
2.
Rerno\-e the d o o r trim upholstery by removing the attachment screws.
Loosen the nut on the lock assembly and remove the lock by turning it sideways.
INSTALLATION OF DOOR LOCK ASSEMBLY.
I . Install the lock in the door by turning it sideways and placing it through the opening p r o ~ ~ d e d
2. Replace the nut on the back of the lock assembly and tighten.
3. Replace the d o o r trim upholstery and secure with the attachment screws.
a
I
DOOR SAFETY (ACXILIARI.) LATCH.
REMOF'AL OF DOOR SAFETY (AC'XILIARY) LATCH.
I . Remove the screw. washer and handle from top outer surface of door.
2. Rerno\e the screuls securing the latch assembly to the inner panel of the d o o r and remo\,e the latch
assembl! .
INSTALLATIOX OF DOOR SAFETY (AUXILIARY) LATCH.
I . Insert hook through the rectangular slot in the top of the door. Align the holes in the latch assembl!.
~ i t hthose in the door inner panel and secure with screws.
2. Install the outer handle. washer and screw.
ADJUSTMENT OF DOOR SAFETY (AUXILIARY) LATCH.
1. T o adjust the d o o r safety latch remove the two screws from latch plate located a t the t o p of the door
opening.
2. Remove the plate and turn the loop assembly in o r out t o make necessary adjustments.
3. Replace the latch plate and secure with the two attachment screws.
52-10-14
Page 52-02
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE MANUAL
I DOOR SNUBBER.
REMOVAL A R D INSTALLATION OF DOOR SNUBBERS.
D o o r snubber seals hace been incorporated in the door jambs t o improve on d o o r sealing. For those
aircraft equipped a s such. the following procedure should be used. If snubbers are not installed. the "Field Kit
f o r Improved Sealing" (763-961 V) should be consulted for installation. if s o desired.
If the existing seal is torn or h d i ) deteriorated, it should be
replaced. I j the seal isfound t o be loose or fhe bondis'9nargina1,"it
should be rebonded. The adhen'ves listed below am recommended
for the rebonding:
1. 3M EC 1300t
2. Scotch Grip 2210
3. Proco #6205-1
Refer to the Lisf of Consumable Materials for vendor information.
I. To remove the snubber proceed as follows:
A. Back off the windlacing trim screws. tape the windlacing back out of the way. remore all scuff
plates and disconnect the d o o r holder.
B. With mineral spirits, soak the edges of the snubber all around the door jamb.
C . With a plastic scraper or other appropriate instrument. scrape off the snubber while appl-ing
mineral spirits a s necessary t o loosen the strip.
D. . U'ith mineral spirits and a clean cloth wipe off all excess adhesive.
1. Before proceeding with the installation, make certain the windlacing is rolled back far enough t o
prevent adhesive from coming in contact with it.
3. Install the snubber a s follows:
A . If the door jamb is flaking o r is excessively scuffed. complete the following repair:
R u b down and feather the finish with "wet o r dry"emery cloth. followed by fine (400 grit)
(I)
paper.
( 2 ) Clean the surface with "Prep-Sol"or other type of cleaner that will not leave a n oil! residue.
( 3 ) Prime. sand (400 grit)and paint the doorjamb. Allow t o dry completely before proceeding.
- NOTES -
Normal tack time/or 3M EC 1300L (used as a rejemnce) is 30 to 45
minutes at IFF. However, odiresive which has "set" may be
reactivated by a clean rag, moistened with toluol or M.E.K.
On forward cabin door make sure leg ojsnubber goes under striker
plate on side latch and over striker pbte for the upper lotch.
On the aft cabin and corgo doors make sure the baggage door is
closed and start at the forward edge oj the d i n door working
upward. Make sure the leg ojthe snubber is under the striker plate.
52-10-16
Pane 52-03
Revised: ~ u ~ u s t - 91984
,
PIPER AIRCR4FT
PA-32-301/30lT
MAINTENANCE MANUAL
.
8862
DO NOT STRETCH SNUBBER
AROUND CORNERS (4 PLACES)
FORWARD CABIN
DOOR INSTALLATION
NOTES
1 SNUBBER BUTT JOINT SHOULD
OCCUR AT DOOR DRAIN AREA AS
APPLICABLE
2 ORIENT SNUBBER FLAT W I T H
SURFACE INDICATED BY NOTE
DESIGNATION
RECOMMENDED
DIRECTION
OF INSTALLATION
TYPICAL
CORNER
SEE
NOTE 1
SNUBBER
VIEW A
I.o..-----.--..---..-----------'
SECTION B - 8
fROTATED 180')
SECTION A - A
SECTION C-C
STRIKER 'SCUFF
PLATE
SNUBBER
SNUBBER
I
I
I
I
I
I
TAPE
I
I
I
I
I
I
I
I
/f-
sE$
NOTE 2
I
ADHESIVE
I
FRAME
a
a
I;
I
I
l
I
I
I
APPLlCATlON OF ADHESIVE
Figure 52- 1. Snubber Installation
52-10-16
Page 52-04
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
BS70
--
AFT CABIN DOOR
INSTALLATION
/---
NOTES
2 ORIENT SNUBBER FLAT WlTH
SURFACE INDICATED WITH
NOTE DESIGNATION
3 TRY TO KEEP WlND LACING AT
LEAST 03 TO 06 IN FROM
SNUBBER
OF INSTALLATION
A
VlEW
WlND LACING
SEE NOTE 2
NOTE
PLATE
SECTION D - D
(ROTATED)
FUSELAGE
SKIN
SECTION E-E
(ROTATED BOO COUNTERCLOCKWISE)
MouLDlNG3
HINGE
CENTERLINE
SEE NOTE 2
WIND LACING
CUT SNUBBER
SNUBBER
+
AFTER ADHESIVE
CURES
OUTBD
?
SECTION F-F
AFT
BAGGAGE
DOOR
FUSELAGE
SKIN
A.
rL
VlEW B
II
F~gure52- 1. Snubber Installation (cont)
52-10-16
Page 52-05
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
.
FORWARD BAGGAGE
DOOR INSTALLATION
mma
FWD
VIEW LOOKING INBOARD
RIGHT HAND SIDE
FUSELAGE SKlN
f
OUTBOARD
-
FRAME
STRIKER PLATE
OVER SNUBBER
SECTION H-H
SECTION G-G
ROTAT ED
-FUSELAGE
SKlN
Figure 52- 1. Snubber Installation (cont)
52-10-16
Page 52-06
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
B. Although not critical. it is recommended that masking tape be applied to the doorjamb at the
borders of the area to be glued. (Refer to Figure 52-1.)
C. Apply adhesive to the door jamb and the inside surface of the snubber. It is recommended that
the snubber be installed before the adhesive becomes tacky so a s to enable manipulation of the snubber.
D. Position the snubber with the protruding leg facing outboard beginning at the door drain area
and working progressively around the jamb applying pressure t o remove any trapped air and insure a proper
bond. DO NOT prestretch the snubber a s this may cause cracks.
E. Wait for at least one day for the bond t o cure. DO NOT allow the door to close. The bond will
cure more efficiently with the door left open and a maximum cure age will be effected.
F. T o check for proper cure try peeling back a small local area of the snubber leg.
G. With the adhesive properly cured. remove the masking tape and clean off excess adhesi\e smears
using mineral spirits or toluol. Install scuff platesand windlacing. If the snubber for the aft cabin door has been
installed. cut snubber a s shown in Figure 52-1.
H. Check that doors close properly and readjust a s necessary to achieve a flush fit. Latching effort
must not have increased.
I. With all hardware and plates reinstalled. coat snubbers with silicone.
CARGO.
1
BAGGAGE DOOR.
REMOVAL O F BAGGAGE DOOR.
With the door open remove the hinge pin from the hinge and remove the door.
INSTALLATION OF BAGGAGE DOOR.
Place the door in position so that the hinge halves are properly matched and install the hinge pin. It w i l l
not be necessary to replace the hinge pin with a new pin if it is free of bends and wear.
I
BAGGAGE DOOR LOCK ASSEMBLY.
REMOVAL O F BAGGAGE DOOR LOCK ASSEMBLY.
I. With the door open remove latch/lock cover and remove the nut from the back of the lock assembl!.
by use of a special made wrench. (This tool may be fabricated from the dimensions given in Chapter 91.)
2. Remove the lock assembly through the front of the door.
INSTALLATION OF BAGGAGE DOOR LOCK ASSEMBLY.
I.
I
Place the lock into position for installation.
2. Install the nut on the lock assembly and tighten with the use of a special wrench.
3. Install the latch, lock cover.
62-30-06
Page 52-07
Revised: ~ u g u s9,t 1984
PIPER AIRCRAFT
PA-32-301/ 30 1T
MAINTENANCE M A N U A L
a
I
BAGGAGE DOOR H I S C E .
R E M O \ ' A L OF BAGGAGE DOOR HINGE.
I.
2.
Rernoic the d o o r from the airplane a s described in Removal of Baggage Door.
Remo\e the hinge half from the airplane o r d o o r by drilling out the ritets and remo\Ing the h ~ n g e .
I S S T A L L A T I O S OF B A G G A G E D O O R H I S G E .
I.
L
3.
rllets.
Place the h ~ n g ehal\es together a n d install the hinge pin.
Install the door into the closed position and drill the two end rivet holes and install the rl\ets.
Operate the d o o r a n d check for proper fit and installation. Drill the r e m a i n ~ n gholes and ~nstallthe
52-30-09
Page 52-08
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 13011
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEFT BLANK
CHAPTER
STABILIZERS
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
CHAPTER 55 STABILIZERS
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTIOX
SUBJECT
55-00-00
GRID
SUBJECT
GENERAL
KO.
EFFECTI\'ITY
2622
STABILATOR
Removal and Installation of Stabilator
Checking Control Surface Free Play
Balancing
Equipment
Stabilator Balancing Procedure
VERTICAL STABILIZER
Removal and Installation of Vertical Fin
RUDDER
Removal and Installation of Rudder
Balancing
Rudder Balancing Procedure
55
- Cont./Effec.
Page - 1
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301130 1T
MAINTENANCE MANUAL
GENERAL.
STABILATOR.
REMOVAL A N D INSTALLATION O F STABILATOR. (Refer to Figure 55-1.)
I
The complete stabilator assembly can be removed by following the procedure given below:
I. Remove the tail cone assembly.
2. Disconnect the stabilator trim link from the trim tab actuator rod.
3. From inside the fuselage disconnect the two stabilator control cables from the stabilator balance arm
assembly. remove trim bracket, loosen trim cables and clamp cables together.
4. Remove the two hinge bolts at the pivot points and remove the stabilator as a complete assembly.
5. Reinstall the stabilator in reverse of removal instructions. Insure proper washer spacing per Figure
55-1, Sketch E. Tension trim cable and stabilator control cables to specifications given in Chapter 27:
CHECKING CONTROL SURFACES FREE PLAY.
The following checks are recommended before balancing to ascertain the amount of "free play" in the
stabilator trim tab and aileron:
I. Stabilator: Check the stabilator for any "fmplay" at its attachment points by grasping each half
near the tip and gently trying to move it up and down, fore and aft, and in and out. No play is allowed.
2. Stabilator Trim Tab: Set the stabilator trim tab in neutral position. This neutral position is
determined with the airplane properly rigged per instructions given in Chapter 27 of this Service Manual and
the trim indicator at its neutral position. Obtain a straightedge long enough to extend from the ground up to a
few inches above the trim tab trailing edge. Place the straightedge next to the trim tab inboard (center) trailing
edge. secure the stabilator in neutral and grasping the tab, gently move it up and down. mark the limit of tab
free play on the straightedge. The overall travel (free play) must not exceed 0.15 of an inch. The use of a dial
indicator and fixed stand is recommended.
Page 55-01
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
Figure 55- 1. Empennage Group
55-20-02
Page 55-02
Issued: Januarv 2. 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
A276
BOLT AN4-6A
WASHER AN960-416L
BOLT AN3-IOA
WASHER AN96G 10 (3 REQ I
A U I
(8 REQ 1
1OROUE 80-100
IN -LBS
SKETCH H
SKETCH G
no
i
BOLT AN3 4 A
WASHER AN96O-10 (UNDER NUT)
NUT MS20365-lOf2C
4 REQ.
T O R W E NUT 36 TO 40 IN.-LBS.
.---------------.-------BOLT N A S 4 6 4 4 A S
WASHER AN960.10 (UNDER NUT1
WASHER AN96O-1OL (UNDER H U D )
NUT MS2 104 5 -L3
4 REQ
T O R W E NUT T O 65 f 5 IN.-LDS
SEE CAUTION
BOLT AN3 4 A
WASHER AN96O-I0 (UNDER NUT)
........................
TORQUE NUT 35 TO 40 IN.-LWi.
BOLT N A U 6 4 P I A 4
WASHER AN96O-10 (UNDER NUT
WASHER AN96O-IOL (UNDER HEAD)
BOLT A N 3 d A
WASHER AN96O-10 (2 RLQ.
UNDER NUT)
WASHER AN960-10
(UNDER HEAD)
NUT MS20165-IO32C
4 REQ
TORQUE NUT I 5 TO 40 IN.&=.
SEE CAUTION
---.--------.-------.---BOLT NAS464 P) A4
WASHER AN96O-10 (1 REQ.
UNDER NUT)
WASHER AN96O-IOL (UNDER HEAD)
NUT MS21046-L3
4 REQ.
TORQUE NUT T O 65 f 5 IN.-LES.
SEE CAUTION
WASHER 9 6 0 4 1 6 L
AS REQ. TO C ~ = R
STAWLATOR A N D
L O C K B U R I N Q INNER
NAS 1104-17 01
BOLT AN1 74-1SA
W m H E R 960416
t i ) UNDER n u n
t1) UNDtR N U T
NUT H 1 0 4
TORQUE 70 T O ) #
SECTION A-A
SKETCH I
W T I O N : IOENTICY HARDWARE
8LFOIL TORQUINQ.
Figure 55-1. Empennage Group (cont)
Page 55-03
Revised: August 19. 1980
PIPER AIRCRAFT
PA-32-301/301~
MAINTENANCE MANUAL
I
BALANCING.
I
EQCIPMENT. (Refer to Chapter 95.)
The balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from
( the centerline of the control surface hinge pin. A suggested tool configuration is shown in Chapter 95. Other
tool configurations may be used. provided accuracy is maintained and recalibration capability is pro\ided.
I
STABILATOR BALANCING PROCEDURE. (Refer to Chapter 95.)
1. Insure that the stabilator is in its final flight configuration. Static wicks. trim tabs, trim tab push pull
rod and control surface tip (as applicable) should be installed. The surface should be painted and trim s e n o
tabs should be in the neutral position.
Because paint is a considerable balonce jactor, it is recommended
that existing paint be removedprior to repainting a control surjace.
2. Place hinge bolts through hinge points and place stabilator on a holding fixture.
3. Avoiding rivets. place the balancing tool on thestabilator with the tool's hinge centerlinedirectl> over
the hinge line of the stabilator.
55-20-05
Page 55-04
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-30 1 / 30 1T
MAINTENANCE MANUAL
4. Adjust the rnoi.able trailing edge support t o fit the width of the stabilator. Tighten the set screu o n the
trailing edge support.
5. Adjust the trailing edge support vertically until the beam is parallel with the stabilator chord line.
6. Remoie the tool from thestabilatorand balance the tool itself by adding o r removing nuts or a as her,
from the beam balancing bolt. When balancing the tool. the movable weight must be at the bar's hinge
centerline.
7. After balancing the tool. reattach i t t o the stabilator. Keep the beam positioned 90' from thecontrol
surface hinge line.
b. Determine balance of stabilator by sliding movable weight along the balance beam.
s
9. Read the scale when the bubble in the level has been centered. Since the movable weight ~ . e i g hthree
pounds. e i e r ) inch i t is moted from the center of the beam equals three inch-pounds of force.
\'ERTICAL STABILIZER.
RE31OVAL A N D ISSTALLATlOh' O F VERTICAL FIN. (Refer t o Figure 55- I . )
I.
R e m o i e the tail cone fairing and fairing a t the forward edge of the fin.
2. Remo\.e the rudder.
3. Disconnect the antenna wire from the antenna assembly.attach a fish line t o the antenna cable before
remo\lng i t from the fin.
4
Separate the stabilator trim cable a t turnbuckle. and remove the cable from the trim m e c h a n ~ s m .
5. Remove the one bolt a t the leading edge of the fin.
6 . Remoie the two bolts which secure the trim mechanism t o the fin spar. Remo\e the four bolts u hich
secure the f ~ nspar t~ the aft bulkhead. Remove the fin.
7 . Install the fin in reverse of remoial instruction using Figure 55- I a s reference for proper harduare and
torques. Check all bolts for safet!.
- NOTE hlodifications to the fuselage are permissible if they do not involve
alterations to the primary structure. I t is recommended that the
manufacturer be contacted for information regarding specific
alterations proposed.
1
REMOVAL A S D IKSTALLATION O F R U D D E R . (Refer t o Figure 55-1.)
I . Remo\,e the tail cone fairing.
2. Disconnect the two control cables from the rudder horn.
3. Disconnect the rudder from the lower rudder hinge bracket.
4. Remo\.e the one remaining hinge bolt. disconnect the tail light electrical wireand remove the rudder.
5. Install the rudder in reverse of removal. check all bolts a n d pins for safety.
Revised: AU~IISI-9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
8927
HOLDING FIXTURE
BALANCING TOOL
BALANCE LIMITS
HEAVY SIDE
LEADING EDGE
H E A W SIDE
TRAILING EDGE
LEVEL SUPPORT
0 I N -LBS
- 1 1 0 IN -LBS
J
i
Figure 55-3. Rudder Balancing
BALASCISG.
The balancing must be done using a suitable tool. such a s that s h o u n In Chapter 95 Other tool
conf~guratlonsma! be used protided accurac} is maintained and recallbratlon capablllt! I S prolldcd
1
R l . D D E R BALASCING PROCEDURE. (Refer to Figure 55-3.)
T o balance the rudder. the assembly must be complete including rudder horn assernbl!. The surface
should be painted and trim servo tabs should be in the neutral position.
Because paint is a considerable balance factor, it is recommended
that existing paint be removedprior to repatrting a controlsurface.
I . Place hinge bolts through hinge points and place rudder on a holding fixture.
3. A\oiding ritets. place the balancing tool on the rudder with the tool's hinge centerline direct]! o \ e r
the hinge line of the control surface.
3. Adjust the mo\able trailing edge support t o fit the width of the rudder. Tighten the set screu on the
trailing edge support.
55-40-03
Page 55-06
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
4.
Adjust the trailing edge support vertically until the beam is parallel with the control surface chord
line.
5 . Remoi-e the tool from the rudder and balance the tool itself by adding or remoling nuts or washer3
from the beam balancing bolt. When balancing the tool. the movable weight must be at the bar's hinge
centerline.
6. After balancing the tool. reattach it t o the rudder. Keep the beam positioned 90' irom the control
surface hinge line.
7. Determine balance of rudder by sliding movable weight along the balance beam.
8. Read the scale w hen the bubble in the level has been centered. Since the mo\able weight weighs three
pounds. every inch i t is moved from the center of the beam equals three inch-pounds of force.
9. S o s e Hea\>: This condition is highly improbable: recheck calculations'and measurementb.
10. Vose Light: In this case. the mass balance weight is too light o r the rudder is too hea\! becaube of
painting: it will be necessary t o strip the paint and repaint. If the rudder is too heavy a s a result of repairs. the
repair must be removed and the damaged parts replaced.
-- END
-
Page 55-07
Revised: August 9. 1984
-
CHAPTER
WINDOWS
PIPER AIRCRAFT
PA-32-301/301T
MAIKTENANCE MANUAL
-
CHAPTER 56 WISDOM'S
TABLE OF CONTENTS/EFFECTI~IT1.'
1
~
I
CHAPTER
SECTIOK
SL BJ ECT
SUBJECT
56- 10-00
56- 10-0 1
56- 10-02
56- 10-03
FLIGHT C O M P A R T M E N T
Windshield
Remotal of M'indshield
Installation of \\'indshield
56-20-00
56-20-0 1
56-20-02
56-20-0.3
C.4BIK
Side \\'indow.s
Remotal of Side Wind0w.s
Initallation of Side U'indows
GRID
\ 0.
EFFECTII'IT)
56
- Cont./Eifec.
-
Page 1
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
FLIGHT COMPARTMENT.
~
I WINDSHIELD.
i
REMOVAL OF WINDSHIELD.
I . Remove the collar molding from around the bottom of the windshield and the trim strip from
between the windshield halves by removing the attaching screws.
2. Remo\.e the windshield by raising the lower portion of the windshield and carefully pulling it out and
dou,nward t o release the top and side edges.
-- NOTE
-
A damaged windshield should be saved since it can be used as a
pattern for drilling reguued holes in the new windshield.
3. Clean the old tape and sealer from the windshield channels. strips and divider post
IRSTALLATION OF WINDSHIELD. (Refer t o Figure 56-1 .)
I . Be certain that the new windshield outside contours are thesarneas that of the old windshield. I t ma!
be found that it is necessary t o cut o r grind the new windshield t o acquire the proper dimensions.
2 . Apply black vinyl plastic tape around the outer edges of the entire windshield.
3. Apply PMS-KO003 Type Ii vinyl foam tape o r equivalent overthe plastic tape.completel! around the
edges of the windshield.
4. Apply PMS-C1012 sealant o r equivalent under the edge of the moldings and trim strips.
5 . Place the windshield in position for installation and slide the windshield aft and up into place. using
caution not to dislocate the tape around the edges. Allow clearance between the two windshields at the di\ ider
po5t for expansion.
6 . Lay sealant at the bottom and center (inboard) of the windshield in the hollow between the outside
edge and channel.
7. La! a small amount of sealant under the center trim strip. install and secure.
8 . Lay black vinyl tape on the underside of the collar molding. install and secure.
9. Seal with sealant any areas around windshield that may allow water t o penetrate past the windshield.
10. Remo\e excess exposed sealer and tape.
CABIV.
I
I
SIDE WINDOWS.
The PA-32-301 301T airplane is equipped with single pane side windows. For removal and installation of
the uindow l;. refer to the following instructions.
56-20-01
Page 56-01
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
.
899
863
a66
WHITE
SEALANT
WHITE
SEALANT
FOAM TAPE
i
VINYL TAPE
A- A
B-B
7 800
/:....,.-- ...-..-.i
1
-
-
--
-
B1
I
I
860
888
867
WHITE S E A U M
WHITE
SEALANT
VlNYL
FOAM TAPE
VlNYL TAPE
VlNYL
FOAM TAPE
BLACK
VlNYL TAPE
0-D
E-E 'IrnL
F-F
L
%
Figure 56- 1 . Windshield Installation (Typical)
56-20-0 1
Page 56-02
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
Figure 56-2. Side Window Installation. Single Pane (1 ?ical)
REMOVAL O F SIDE WINDOWS.
I.
S ~ n g l ePane
A . Rem0i.e the retainer molding from around the window by remobing the attachment s c r e u s
8 . Carefull! r e m o \ e the windou from the frame.
A damaged window should be saved toprovide apatternfor shaping
the new window.
C. Remove excess tape a n d sealer from the window frame a n d molding
56-20-02
Page 56-03
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-3011301T
MALNTENANCE M A N U A L
I S S T A L L A T I O S OF S I D E WINDOWS.
I.
Single Pane (Refer to Figure 56-2.)
A. Cut or grind the new window t o the same dimension a s the window remo\.ed.
B. Appl! PUS-KO003 Type I I vinyl foam tape number 560 or equi\,alent on both sides o i the
window around the outer edges.
C. Appl! P U S - C 1012 Sealant or equivalent completelyaround the outer surface of the w indow s at
all attachment flanges.
D. Insert the w.indow in the frame and install the retainer moldings.
E. Secure the molding with attachment screws and tighten until the vinll foam tape is 2 5 5
compressed by the retainers.
F. Remo\.e the excess exposed sealer a n d tape.
56-20-03
Page 56-04
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
GRIDS 2 H l l T H R U 2H13 INTENTIONALLY LEFT BLANK
CHAPTER
WINGS
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 57 WINGS
TABLE O F CONTENTS/EFFECTIVITY
CHAPTER
SECTIO\
SUBJECT
SUBJECT
GRID
N 0.
EFFECT\'ITI'
GESERAL
Debcription
AUXILIARY STRUCTURE
H'ing Tip
Rerno~alof Wing Tip
Installation of Wing Tip
Repair of Wing Tip
ATTACH FlTTlSGS
U'ing Attach Fittings
Rernoial of H'ing
Installation of Wing
57-50-00
5'-50-0 1
5'-50-03
57-50-0;
57-50-04
57-50-05
57-50-06
57-50-0'
57-50-08
57-50-09
FLIGHT SCRFACES
A~leron
Remoial of Aileron
lnstallat~onof Aileron
Checking Aileron Free Pla)
Balanc~ng
Aileron Balancing Procedure
H'lng Flap
Rernoial of H'ing Flap
lnstallat~onof n'lng Flap
57
- Cont./Effec.
Page - 1
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
This chapter explains the remo\al and installation procedures for the wings and related components
in3talled on this aircraft.
DESCRIPTION.
Each wing panel is an all metal. full cantilever. semi-monocoque type structure with remo\.able tips and
access panels. Attached t o each v;ing are the aileron. flap. main landing gear and fuel tank. The wings are
attached t o each side of the fuselage by inserting the butt ends of the mainspars into a spar boxcarry through.
The spar box is an integral p a n of the fuselage structure which provides. in effect. a continuous main spar w i t h
splices at each side of the fuselage. There are also fore and aft attachments at the front and rear spars.
The major subassemblies of the wing may be removed individuallv
or the wing mav be removed as a unit. To remove a wing, afuselage
and wing supporting cradle is rquired.
(
WING TIP.
R E M O l ' A L O F W I S C TIP.
1.
Remo\e the screns holding the a.ing tip t o the wing. being careful not t o damage the wing or w ing tip.
2. Pull off the w ing tip far enough t o disconnect the position and strobe light wire assembl!. The ground
lead ma! be disconnected at the point of connection on the wing rib. and the positive lead ma! be disconnected
at the wire terminal o r unscrewed from the light assembly.
3. Inspect the w.ing tip t o ascertain that it is free of cracks. severe nicks and minor damage. I f repair i3
required. refer to Chapter 51.
INSTALLATION O F H'ING TIP.
I . Place the wing tip in a position that the navigation and strobe light leads may be connected. Connect
the ground lead to the wing rib by use of a screw and nut. and the positive lead to the position light b!
connecting the wire terminals o r screwing the connectors together. Insulate the wire terminals and be certain
that the ground lead is free of dirt and film to insure a good connection.
2. Insert the wing tip into position and install the screws around the tip. Use caution to refrain from
damaging the wing tip or wing. Check operation of the lights.
REPAIR O F H'ING TIP.
Badly damaged thermoplastic tips should be replaced. (Refer t o Chapter 51.)
5F2CO4
Page 57-01
Revised: ~ u ~ u9.s 1984
t
PIPER AIRCRAFT
PA-32-301/ M l T
MAINTENANCE MANUAL
I
BOLT LEGEND
WASHER
I
POSITION
A1
A2
A3
A4
A5
BOLT
NUT
UNDER HEAD
UNDER NUT
NAS464P6LA17
NAS464P6LA16
i NAS464P6LA16
NAS464P6LA16
NAS464P6LA16
NAS464P6LA15
NAS464P6LA14
NAS464P6LAl4
NAS464P6LA14
NAS464P6LA14
NAS464P5LAZO
NAS464P6LAZO
NAS464P6LAZO
NAS464P6LA20
NAS464P6LA21
NAS464P5LA21
NAS464PSLA20
NAS464P6LA20
NAS464P6LA20
NAS464P6LA20
NAS464P6LA21
NAS464P5LA21
' MS2 1042-6
I MS21042-6
AN960-616
AN960-616
AN960-616
AN960-616
AN960-616
AN960-616L
AN960416
AN960-616
AN960-616
AN960-616
AN960-516L
AN960-616L
AN960-616L
AN960-616L
AN960-616L
AN960-516L
AN960-516L
AN960-616L
AN960-616L
AN960-616L
AN960-616L
AN960-516L
AN960-616 (2 Max)
AN960-616 (2 Max)
AN960-616 (2 Max)
AN960-616 12 Max)
AN960-616 (2 Max)
K19301-6
K19301-6
K19301-6
K19301-6
Kt9301 -6
AN960-516 (2 Max)
AN960-616 (2 Max)
AN960-616 (2 Max)
AN960-616 (2 Max)
96352-3
96352-2
AN960-516 (2 Max)
AN960-616 (2 Max)
AN960-616 (2 Max)
AN960-616 (2 Max)
96352-3
96352-2
, :: I
I
,
83
84
05
C1
C2
C3
C4
C5
C6
Dl
02
03
04
05
D6
MS21042-6
MS21042-6
MS21042-6
H I 9300-6
H193W-6
H19300-6
H19300-6
H19300-6
MS21042-5
MS2 1042-6
MS21042-6
MS21042-6
MS21042-6
MS21W2-5
MS21042-5
MS21042-6 1
MS21042-6
MS21042-6
MS21042-6
MS21042-5
I
I
I 6 2 oh
0-1 0-3 0-5
TORQUE BOLT HEADS ON UPPER SPAR CAP & NUT ON LOWER SPAR CAP
AS FOLLOWS
5/16 INCH BOLT = 205.225 IN-LBS
318 INCH BOLT = 360-390 IN-LBS
0-6
SKETCH C
w
Am7
am
A-5 A4 A-3 A.2
I
I
C.5
I
I
C-3
A-1
I
C-1
SKETCH D
Figure 57- 1 . Wing Installation
57-20-04
Page 57-02
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANL'AL
SECTION A-A
--NUT - MS21042-6
1 MAXIMUM NUMBER OF WASHERS AUOWED BETWEEN FORWARD FACE
OF WING FrlTlNG AND AFT FACE OF FUSELAGE FllTlNG IS ONE
AN960-616L AND ONE AN960-616
2 ALL THREE WASHERS USED IN A n W l N G AlTACHMENT FIlTING ALWAYS
REQUIRED WITH ONLY THE A N W - 6 1 6 L WASHER ALLOWED UNDER
F ~ g i ~ r57c I. W'ing Installation (con[)
Page 57-03
Revised: August 9,' 1984
PIPER A I R C R A F T
PA-32-3011301T
MAINTENAVCE MANUAL
ATTACH FITTIYCS.
I WISG ATTACH FITTINGS.
REMO\'AL O F WING. (Refer t o Figure 57-1.)
I . Close the fuel\al\e and drain the fuel from the wing t o be removed. (Refer t o Draining Fuel S!3tem.
Chapter 12.1
2. Drain the brake line and reser\.oir. (Refer t o Draining Brake System. Chapter 12.)
3. R e m o \ e the access plate a t the wing butt rib and wing inspection panels. (Refer to Access Plate4 and
Panels. Chapter 6 . )
4. R e m o t e the front and back seats from the airplane.
5 . Expose the spar box and remove the cockpit side trim panel assembly that corresponds u ith the u ing
being remo\ed.
6. Place the airplane on jacks. (Refer t o Jacking. Chapter 7.)
- NOTE To help jacilitate reinstallation of control cables, and juel lines.
mark cable and line ends in some identijying mcurner and attach a
line where applicable to cables before drawing them through the
fuselage or wing.
7 . Disconnect the aileron balance and control cables at the turnbuckles that are located u ilhin rhc
fuselage aft of the spar.
8 . I f the left u.ing is being remo\ed. remo\e the cotter pin from the pulle! bracket assembl! to allou the
left aileron balance cable end to pass betu.een the pulley and bracket.
9. Disconnect the flap from the torque tube by extending the flap t o its fullest degree. and remo\ ing the
bolt and bushing from the bearing at the aft end of the control rod.
10 Disconnect the fuel line at the fitting located forward of the spar at the u ing butt line.
To prevent damage or contamination of juel, and miscellaneous
lines, place a protective cover over the line fittings and ends.
I I . Remo\ e the clamps necessary t o release the electrical harness assembly. Disconnect the leads from
the terminal strip assembly by removing the cover. and appropriate nuts and washers.
I?. With the appropriate trim panel remo\.ed. disconnect the hydraulic brake line at the fitting located
u.ithin the cockpit at the leading edge of the wing.
I f . I f the left wing is being remo\,ed. it will be necessary to disconnect the pitot static tube at the elhow.,
located within the cockpit at the wing butt line.
14. Arrangea suitable fuselage cradle and supports for both wings.
IS. Remo\.e the jacks.
16. Rern0t.e the front and rear spar nuts. washers and bolts.
17. Remo\e the twent!.-two main spar bolts.
18. Slow !I remo\e the wing being certain that all electrical leads. cables and lines are disconnected.
57-40-02
Page 57-04
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
- -
-
INSTALLATION O F WING. (Refer to Figure 57-1.)
1. Ascertain that the fuselage is positioned solidly on a support cradle.
2. Place the wing in posiiion for installation, with the spar end a few inches from the side of the fuselage
and set on trestles.
3. Prepare the various lines. control cables, etc., for inserting into the wing or fuselage when the wing is
slid into place.
4. Slide the wing into position on the fuselage.
5, Install the twenty-two main spar bolts in accordance with the bolt legend.
-- NOTE
-
W k n rcplachg a wing assembly, oocrrtain the wing butt c l ~ ~ ~ aisn c c
mainraind. (Rcjer to Sketch A, Figure 57-1.)
6. Install the bolt. washers and nut that attaches the front spar with the fuselage fitting. A minimum of
one washer is required under the nut, then add washers as needed to leave a maximum of one and one-half
threads visible or a minimum of the bolt chamfer exposed.
7. Insert the number of washers required between the forward face of the wing fitting and aft face of the
fuselage fitting. The maximum number of washers allowed is one AN960-616Land one AX960-616. I t is also
acceptable to have the faces of the fittings against each other. After the required washers are inserted between
the plates. install the bolt and check to insure that no threads are bearing on the forward plate prior to
installing the nut. Use the shortest bolt which will lcave0.580 of an inch minimum from the fitting to the end of
the bolt. Add washers, AN960-616. as required, (minimum of one), to leave a maximum of one and one-half
visible thread. or minimum of the bolt chamfer exposed after the nut is torqued.
8. Torque the twenty-two main spar bolt nuts or bolt heads (51 16 inch bolt. 205-225 in. Ibs.: 3 8 inch
bolt, 360-390 in. Ibs.). Be cenain that the bolts, nuts and washers are installed in accordance with the bolt
legend. The forward spar attachment bolt should be torqued 50-60 inch pounds. Torque the rear spar
attachment bolt from 360 to 390 inch-pounds.
9. Install the wing jacks and the tail support to the tail skid with approximately 250 pounds of ballast on
the base of the tail support. Remove the fuselage cradle and wing supports.
10. If the left wing was removed. it is necessary that the pitotlstatic tube to be connected at the elbows
located within the cockpit at the wing butt Line. Replace or install clamps where found necessary. In the event
that a heated pitot is installed. the plus lead must be connected at the fuselage.
I I . Connect the hydraulic brake line onto the fitting located within the cockpit at the leading edge of the
wing.
12. Connect the leads to the appropriate posts on the terminal strip and install the washers and nuts.
assistance in connecting the electrical lead, refer to the Electrical Schematics in Chapter 9 1.) Place the clamps
along the electrical harness to secure it in position and install the terminal strip dust cover.
13. Remove the cap from the fuel line and connect it at the fitting located forward of the spar at the wing
butt line.
14. Connect the aileron balance and control cables at the turnbuckles that arc located within the fuselage
aft of the spar. After the left balance cable has been inserted through the bracket assembly and connected.
install a cotter pin cable guard into the hole that is provided in the bracket assembly.
15. Connect the flap by placing the flap handle in the full flap position, place the bushing on the outside of
the rod end bearing and insert and tighten bolt.
16. Check the rigging and control cable tension of the ailerons and flaps. (Refer to Rigging and
Adjustment of Ailerons. and Rigging and Adjustment of Flaps, Chapter 27.)
or
Page 57-01
Revised: August 9. 1984
a
PIPER AIRCRAFT
PA-32-301 ,'301T
MAINTENANCE MANUAL
2
t
M84
8883
8882
SKETCH A
-
4
I
-
NUT MS20365-1032C
AlLEROk
m m
-
BOLT AN3-7A
WASHER
- AN-10
WASHER
- AN970-3
SKETCH 6
-
BOLT AN3-11A
WfiHER AN860-1OL
WASHER AN960-10 (21
NU ~ ~ 2 0 3 6 5 - 1 0 3 2 C
-
-
-
Figure 57-2. Aileron and Flap Installation
57-4&03
Page 57-06
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
BOLT AN3-12A
WASHER AN960- 10
BUSHING 63900-38
1
I
I
Figure 57-2. Aileron and Flap Installation (cont)
Revised: ~ u ~ u o t - 91984
.
PIPER AIRCRAFT
P.9-32-301/301T
MAINTENANCE MANUAL
17. S e n ice and refill the brake s!,stem with hydraulic fluid in accordance with S e n k i n g Brake S! stem.
Chapter 12. Bleed the system as gi\.en in Chapter 32 and check for fluid leaks.
18. S e n i c e and fill the fuel system in accordance with Sen.icing Fuel System. Chapter 12. Open the fuel
\.al\.e and check for leaks and flow.
19. Check the operation of all electrical equipment. and pitot system.
20. Remo\e the airplane from the jacks.
21. Install the cockpit trim panel assembly. spar box carpet. the front and back seats. and w.ing butt
rubber molding.
22. Replace all the access plates and panels o n the wing involved.
FLIGHT St:RFACES.
I AILEROS.
REMOVAL O F AILERON. ,(Refer t o Figure 57-2.)
I . Disconnect the aileron control rod a t the aileron attachment point by remo\ ing the nut. washers and
bolt from the rod end bearing. T o simplif! installation note location of washers remo\ed.
2. Remo\e the nuts. washers and bolts from the hinges of the aileron. and remo\e the a ~ l e r o n .
INSTALLATION O F AILEROh'. (Refer t o Figure 57-2.)
I . M o \ e the aileron into place and install the bolts. washers and nuts in the aileron hinges. .4scerta1n
that the aileron is free t o move with no interference.
2. Attach the aileron control rod with bolts. washers and nut. dividing the washers so that the aileron is
free to rotate from stop t o stop w.ithout the control rod binding o r rubbing on the opening in the aft spar. Be
certain that the rod end bearing has no side play when tighteningthe bolt and that the rod does not contact the
side of the bracket.
3. Actuate the aileron controls t o insure freedom of movement.
CHECKING AILEROK FREE PLAY.
The following checks are recommended before balancing t o ascertain the amount of "free pla!" in the
aileron:
Set the aileron in its neutral position and secure. Obtain a straightedge long enough t o extend from the
ground up to a few inches above the aileron trailing edge. Place the straightedge next t o the aileron trail~ng
edge and gentl! mo\e the aileron u p and down. mark the limit of travel (free play) on the straightedge. The
o\erall tra\el (free play) must not exceed 0.24 of a n inch. Should free play exceed the limit stated mahe
necessar! repairs as required t o eliminate free play. Grasp the aileron and m o \ e it spanwlse
(inboard outboard) t o insure maximum end play of .035is not exceeded.
51-5b04
Page 57-08
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-.
.- ..---
HEAW SIDE
LEADING EDGE
H E A W SIDE
TRAILING EDGE
-14.7 LBS.
Figure 57-3. Aileron Balance Configuration
BALANCING.
AILERON BALANCING P R O C E D U R E . (Refer t o Figure 57-3.)
Position the aileron on the balancingfixture in a draft free area a n d in a manner which allows unrestricted
movement of the aileron. Place the tool o n the aileron. avoid rivets and keep the beam perpendicular t o the
hinge centerline. Read the scale when the bubble level has been centered by adjustment of the moiable weight
and determine the static balance. If the static balance is not within the limits specified in Figure 57-3. proceed
as follows:
I. Leading Edge Heavy: This condition is highly improbable: recheck measurements and calculations.
2. Trailing Edge Heavy: There are n o provisions for adding weight t o balance weight t o counteract a
trailing edge heavy condition: therefore. it will be necessary t o determine the exact cause of the unbalance. If
the aileron is too heavy because of painting over old paint. it will be necessary t o strip all paint from the aileron
and repaint. If the aileron is t o o heavy resultingfrom repair t o the skin o r ribs. it will be necessary to replace all
damaged p a n s and recheck the balance.
Page 57-09
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
REMOVAL O F WING FLAP. (Refer t o Figure 57-2.)
1 . Extend the flaps to their fullest degree and remove the bolt and bushing from the rod end bearing b!
use of an angle o r offset screwdriver.
2 R e m o ~ ethe nuts. washers. bushing and hinge bolts that hold the flap t o the wing assembl).
3. Pull the flap straight back off the wing.
INSTALLATION OF WING FLAP. (Refer t o Figure 57-2.)
1 . Replace the wing n a p by placing the flap o n t o its proper position and inserting the hinge bolts.
bushings. u.ashers and nuts.
7. With the flap control in the full flap position. place the bushing o n the outboard side of the rod end
bearing and insert and tighten the bolt.
3. Operate the flap se\.eral times t o be certain it is operating freely.
- END -
57-50-09
Page 57- 10
Revised: August 9. 1984
CHAPTER
PROPELLER
PIPER AIRCRAFT
PA-32-30 1/30 1T
MAINTENANCE MANUAL
CHAPTER 61
- PROPELLERS
TABLE OF COKTENTS/EFFECTIVITY
CHAPTER
SECTIO\
SL'BJECT
SUBJECT
GRID
SO.
EFFECTI\.ITI
PROPELLER ASSEMBLY
Maintenance of Propeller
Rerno\al of Propeller
Cleaning. Inspection and Repair of Propeller
Installation of Propeller (PA-32-30 1 )
Installation of Propeller (PA-32-301T)
Blade Track
COXTROLLISG
Propeller Governor
Rerno\al of Propeller Go\.ernor
lnstallation of Propeller Governor
Rigging and Adjustment of Propeller Governor
61
- Cont./Effec.
Page - 1
Revised: August 9. 198.1
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
An69
E x b t t E R r T E O VIEW OF
~ I C KI N L E A D I N G EDGE
EMGGEllATEO VIEWOF
S U F A Q CRACK
-
\
CIOSSStCTlON
m a r o a t IEVAIR
EXAGGERATED VIEW 0 6
NICK I N FACE OF @ L A M
-
EDGE ALIOWYCNT WIT*
s u o o l r CURVCS
VOTE
C I O 1 I SECTlOI I T C I ncvbln
RECOMMEND€ D M E T H O D FOR R E Y O V I N G N I C l t .
C R A C K S A N D S C R I T C H E S I S B V USING R I F F L E
FILE A N D OR CROCUSCLOT*
Figure 61-1. Typical Nicks and Remo\.al Method
GENERAL.
PROPELLER ASSEMBLI'.
I YAI\.TESASCE
O F PROPELLER.
Included in this section are procedures for the remo\al. installation. cleaning. inspection. repalr a n d
tracking of the propeller.
RE!tIO\'AL O F PROPELLER.
I. Inwre t h i t the master and magneto switches are off.
1. V o \ e fuel selector to off position.
1. Place the mixture control in idle cut-off.
Kote position of each component to facilitate reinstallation.
Rem0t.e the s c r e w from around the spinner assembly and remove spinner.
6. Remo\.e the caret!. wire from the propeller mounting nuts on studs and remote hrud4.
7 . Place a drip pan under the propeller to catch oil spillage. then remo\e the propeller.
4.
5.
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL.
61-10-02
Page 61-02
Revised: .4ugusf 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
SCREW SPINNER ATTACHMENT
SPINNER DOME [HARlZELL C-4548)
ADAPTER RING
FILLER PLATE (HARRELL 0-4522)
ADAPTER RlNG BOLTS
HUB ATTACHMENT BOLTS
STARTER RlNG
LOW PITCH STOP
SAFETY WIRE
PROPELLER HUB
PROPELLER BLADE
0830
TORQUE
6 0 TO 7 0
n LBS.
20-25 IN LBS
NOTES.
LOCATION OF BOLT HOLE MARKED "0" WHEN U l PISTON IS ON TOP DEAD CENTER INSTALL PROP WITH
BLADES INDEXED WITH BOLT HOLES AS SHOWN
BUSHINGS ARE FLUSH OR RAISED AS INDICATED
8804
FLUSH
/ - - -
"0" MARK
(SEE NOTE 1)
(SEE NOTE 2)
F ~ g u r e61 -3. Three Blade Propeller Installation (PA-31-301 )
61-10-02
Page 61-03
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAIYTENANCE MANUAL
61 -1 0-02
Page 61-04
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
1 SPINNER DOME
2 FILLER PLATE
3 SPINNER AllACHMENT SCREW
4 LOW PITCH STOP SCREW
5 PROPELLER HUB
6 PROPELLER BLADE
7 SPINNER BULKHEAD
8 BULKHEAD AnACHMENT BOLT,
WASHER SPACER AND NUT
9 PROPELLER HUB CHAFING RING
1 0 CLAMP (SEE NOTE 3)
11 SAFEN WIRE
IN LBS
NOTE 1
m u
FLUSH
I
/ - - -
NOTES
1 APPLY GENEROUS BRUSH COATING OF EC776TO E
TIRE CIRCUMFERENCE OF PROPELLER HUB FOR Dl
TANCE SHOWN INSTALL PROPELLER HUB CHAFING
RING WlTHlN 1 0 MINUTES OF APPLICATION OF
COATING
2 LOCATION OF BOLT HOLE MARKED "0" WHEN I 1 PISTON IS ON TOP DEAD CENTER INSTALL PROPELLER
WITH BLADES INDEXEDWITH BOLTHOLESAS SHOWN
3 CLAMPS SHOULD BE INSTALLED WITH THE WORM
GEAR HOUSINGS 180' OPPOSITE TO EACH OTHER
4 "0" HOLE REQUIRES RAISED BUSHING. A U OTHER
BUSHINGS ARE AS INDICATED
\
Figure 61-5. Three Blade Propeller Installation (PA-32-30 IT)
61 -1 0-02
Pane 61-05
Revised: ~ u ~ u s I - 91984
.
PIPER AIRCRAFT
PA-32-301 1301 T
MAINTENANCE M A N U A L
C H A R T 610 I . P R O P E L L E R S P E C I F I C A T I O X S (PA-32-301 )
2 BLADE
HC-C2Y K- I B
F F8475D-1
RO in.
3 B1.ADE
HC-C?Y R - l r
F F7663R-0
78 in.
13.5O 2 0.2O( 1 )
34.0° 2 I .OO( I )
12.4' 2 0.2O( I
32O 2 I C ( I )
Propeller R P M
Setting
Engine Static High R P M
2700 R P M m a \ .
Propeller T o r q u e
I imit~
Description
H u h . %lodcl
Rladc. 'Ll odcl
D~ametcr
R l i i d ~4nglc
1.w Pitch ( High R P X I )
High P ~ t c h( [.ow R P M )
)
)
Required T o r q u e
( Dr! )
Propeller Mounting K u t s
F u d . Bulkhead Attachment
Bolts
Spinner Attachment S c r e u s
60-70 foot-pound4
30-35 inch-pound\ ( 2 1
20-25 inch-pound\
I I 5le;i*urement taken at 3 0 inch radiu4
( 2 ) ? blade in\lallation onl!
(
J
C H A R T 6102. P R O P E L L E R S P E C I F I C A T I O K S (P.4-32-30IT)
H u b . \lode1
Rlade. 51 ode1
D~ameter
Rl;~de.Angle
I n\\ Pitch r H ~ g hR P 5 1 )
H lgh Pltch ( L o \ \ R P\1)
2 BLADE
HC-E'YR-I
F F8477-4
H0 in.
(
1
3 BL.4DE
HC-E3Y R- l r
F F7673DR-0
78 in.
)
1 5.hc 2 0.2O( I )
34.0' 2 1 .OO( 1 )
13.2' 2 0.2'( I
34.5= 2 I C ( I )
Propeller R PA1
Setling
Engine Static High R P M
2700 R P M m a \ .
Propeller Torque
I.imir~
Description
Required T o r q u e
(Dr! )
60-70 foot-pound\
20-25 inch-pound4
20-22 foot-pound\ r 2)
Propeller Mounting \ u t s
Spinner Attachment Screws
Propeller Bulk head
Attachment Bolts
)
r l r 3le~14urementtaken at 30 inch radius
( 2 ) 2 hlade initallation onl!.
61 -1 0-02
Page 61-06
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CLEANING, INSPECTION AND REPAIR O F PROPELLER.
1 . Check for oil and grease leaks.
2. Clean the spinner. propeller hub interior and exterior. and blades with a non-corrosive sol\ent.
3. Inspect the hub pans for cracks.
4. Steel hub parts should not be permitted t o rust. Use aluminum paint to touch up if necessan. or
replate during overhaul.
5. Check all visible pans for wear and safety.
6. Check blades to determine whether they turn freely on the hub pivot tube. This can be done by
rocking the blades back and forth through the slight freedom allowed by the pitch change mechanism. I f the!
appear tight and are properly lubricated. the pitch change mechanism should be remo\ed so that each blade
can be checked individually. If blades are tight. the propeller should be disassembled.
7. Inspect blades for damage or cracks. Nicks in leading edges of blades should be filed out and all edges
rounded. as cracks sometimes stan from such places. Use fine emery cloth for finishing. Refer to Figure 6 1- I
for propeller blade care.
I INSTALLATION OF PROPELLER. (PA-32-301)
1 . Insure master and magneto switches are off.
2. Place fuel selector to off position.
3. Place mixture control in idle cut-off.
4. Observe the staner ring p a r to make sure it is mounted properly on the engine crankshaft flange. One
of the bushings on the crankshaft is stamped with an "0"mark and it must be inserted in the staner ring gear
hole. likewise identified with an "0"mark.
5. Wipe crankshaft and propeller pilot to assure that no chips or foreign matter enter the propeller
mechanism.
6. Check interior of propeller hub for proper seating of O-ring. Wipe inside of hub to remob-ean!. traces
of dirt. Check to see that O-ring is covered with grease.
7. lnstall prop with blades aligned with mounting bolt hole marked "0".
8. lnstall rear spinner bulkhead.
9. Slide propeller carefully over pilot. taking care that O-ring is not damaged.
10. lnstall the six hexagon head propeller hub mounting bolts and torque per Chart 6 101.
I I . Check propeller blade track as given in Blade Track.
I . Safety the propeller mounting bolts with MS20995-C41 safety wire.
13. Grease blade hub through zerk fittings. Remove one of the two fittings for each propeller blade.
alternate the next time. Apply grease through the zerk fitting until fresh grease appears at the fitting hole oft he
removed fitting. Care should be taken t o avoid blowing out hub gaskets.
14. lnstall the forward spinner bulkhead and torque bolts per C h a n 6101. Safety bolts with MS20995C41 safety wire.
15. lnstall spinner and spinner cuff. Torque all attachment screws per Chart 6101.
61 -10-04
Page 61-07
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 1301 T
MAIPTTENANCE MANUAL
1
ISSTALLATIOS OF PROPELLER. 1 P.4-??-3OlT)
I . Inrure ma\ter and magneto switches are off.
2. Place fuel \elector t o off position.
3. Place misture control in idle cut-off.
4. Ohsrtr\e the starter ring gear t o make sure it is mounted properl!on the engine crankshaft flange: One
o f the bushing\ o n the crankshaft is stamped with an "0"mark and it must be inserted in the starter ring gear
hole. likeu ise identified u ith an "0"mark.
5 . Wipe crankshaft and propeller pilot t o assure that no chips o r foreign matter enter the propeller
mechanism.
6. Check interior of propeller hub for proper seating of O-ring. Wipe inside of hub t o remo\e an!. tracer
of dirt. Check t o see that O-ring is covered with grease.
7. Install rear spinner bulkhead.
P. Appl! a generous brush coating of EC776 adhesi\.e t o the entire circumference of propeller huh for
distance as 5houn in Figure 614. Sketch A.
-NOTE EC776 adhesive coating can be purchased through the Minnesota
Mining and Manujacturing Company, St. Paul, Minnesota.
Propeller hub must be clean, dry and free from oil or grease.
9. I n ~ t a l lpropeller hub chafing ring within ten minutes of application of coating.
10. InNtall and secure clamps around chafing ring. (Refer t o Figure 61-4. Sketch 4 for propcr
1nrtallation.l
I I . Slide propeller carefull! o \ e r .pilot. taking care that O-ring is not damaged.
12. In\tall the hexagon head propeller hub mounting bolts and torque per Chart 6102.
I!.
Check propeller blade track as gi\en in Blade Track.
14. Safet! the propeller mounting bolts u.ith MS20995-C41 safety u ire.
15. Grease blade hub through 7erk fittings. Remove one of the two fittings for each propeller bladt.
alternate the next time. Apply grease through the zerk fitting until freshgreaseappearsat the fitting hole of the
remo\ed fitting. Care should be taken t o a\,oid blowing out hub gaskets.
16. Install spinner and spinner cuff. Torque all attachment screus per Chart 6102.
BLADE T R A C K .
Blade track is the abilit!. of one blade tip to follow the other. while rotating. in almost the same plane.
Euce\si\e difference in blade track - more than .Oh25 inch - may be an indication of bent blades o r improper
propeller installation. Check blade track as follows:
I . N'ith the engine shut down and bladesvenical. secure t o the aircraft a smooth board just under the tip
of thc louer blade. M o \ e the tip fore and ; ~ f through
t
its full "blade-shake"tra\el. making small mark\ 14 ~ t ha
pencil at each position. Then center the tip between these marksand scribea line on the board for the full w ~ d t h
of the tip.
2. Carefull!- rotate propeller by hand t o bring the opposite blade down. Center the tip and scribe a pencil
line a r before and check that lines are not separated more than ,0625 inch.
61 -1 0-06
Page 6 1-08
Revised: August 9. 1981
PIPER AIRCRAFT
PA-32-301/ 30 1T
MAINTENANCE MANUAL
3. Propellers having excess blade track should be removed and inspected for bent blades. or for pans of
sheared O-ring. or foreign panicles. which have lodged between hub and crankshaft mounting faces. Bent
blades will require repair and overhaul of assembly.
CONTROLLING.
PROPELLER GOVERNOR.
REMOVAL OF PROPELLER GOVERNOR.
1. Remove the upper engine cowl.
2. Disconnect the control cable end from the governor control arm.
3. Remove the governor mounting stud nuts. It will be necessary to raise the govemor as the nuts are
being removed before the nuts can be completely removed.
4. Remove the mounting gasket. If the governor is to be removed for a considerable length of time and
another unit not substituted. it is advisable to cover the mounting pad to prevent damage caused by foreign
matter.
INSTALLATION OF PROPELLER GOVERNOR.
I. Clean the mounting pad thoroughly, making very certain that there are no foreign panicles in the
recess around the drive shaft.
2. Place the governor mounting gasket in position with the raised portion of the screen facing away from
the engine.
3. Align the splines on the governor shaft with the engine drive and slide the govemor into position.
4. With the governor in position, raise the governor enough to install washers and stan mounting nuts.
Torque nuts even.
5. Connect the control cable end to the governor control arm. The ball stud is installed in the inner hole
of the control arm.
6. Adjust governor control per Rigging and Adjustment of Propeller Governor.
7. Install engine cowl.
RIGGING AND ADJUSTMENT O F PROPELLER GOVERNOR. (Refer to Figure 61-6.)
I. Prior to adjusting the propeller governor high R P M setting. the control linkage should be thoroughly
checked for correct function.
-- NOTE
-
A calibrated tachometer must be used to ascertain propeller high
RPM setting. Final high RPM adjustment must be checked inf fight
or during high speed taxi.
To check rigging. move propeller control full forward. The propeller governor high RPM stop must
contact the adjusting screw when the cockpit control is 0.0 I0 to 0.030 inch from the cockpit mechanical stop. If
adjustment is required complete the following steps.
61-20-04
Page 61-09
Revised: May 21, 1980
PIPER AIRCRAFT
PA-32-301 / 30 1T
MAINTENANCE MANUAL
A066
1. CONTROL ARM
2 . RPM ADJUSTMENT I C R E W
1. CONTROL WHEEL
4 . LOCK N U T
5 . 8 O L T ASSEMBLV
•
LOW
060
m~cn
I M T A L L CABLE E N D
STUD IN THIS n o L
Figure 6 1-6. Propeller Governor
A. Insure that the governor control arm is located approximately as shown on Figure 61-6.
B. Adjust control cable end hardware to obtain cockpit control cushion. Insure there is adequate
thread engagement of clevis end and rod end bearing (witness holes) after adjustment.
C. Insure that the control cable assembly is not bottoming internally.
2. Stan engine. park 90' to wind direction and warm in normal manner.
3. To check high RPM. low pitch setting, move the propeller control all the way forward. At this
position the governor speed control arm should be against the high RPM fine adjusting screu. W ~ t hthe
throttle full forward. observe engine RPM, which should be adjusted as follows:
A. Shut down the engine and remove the upper engine cowl.
B. Adjust the governor by means of the fine adjustment screw for 2700 RPM. To do this. loosen the
high RPM fine adjustment screw locknut and turn the screw in a clockwise direction to decrease engine speed
or in a counterclockwise direction to increase engine speed.
-- NOTE
-
One revolution of theme adjustment scnw will increase or decrease
the engine speed approxhately 20 RPM.
C. Reinstall upper engine cowl and repeat Step b to ascertain proper RPM setting.
61-20-04
Page 61-10
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
D. After setting the proper high RPM adjustment. run the self-locking nut on the fine adjustment
screw against the base projection to lock.
E . Abcertain that the governor control arm is adjusted to the proper angle on the control u.heel as
shown in Figure 61-6.
5 . With the high R P M adjustment complete. the control system should be adjusted so that the go\ ernor
control arm will contact the high RPM stop when the propeller lever is 0.010 to0.030ofan inch from foruard
stop on the power quadrant. T o adjust the control travel. disconnect the control cable end from the control
arm. loosen the cable end jam nut and rotate the rod end to obtain the desired lever clearance. Reconnect the
cable end and tighten jam nut.
6. I t is usuall!. only necessar? to adjust the high RPM setting of the governor control sFstem. as the
action automaticall!. takes care of the positi\.e high pitch setting.
- END -
61-10-04
Page 61-11
Issued: Janunr! 2. 1980
CHAPTER
STANDARD PRACTICES
ENGINES
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
--
-
-
CHAPTER 70 STANDARD PRACTICES ENCIIVES
TABLE OF COIVTENTS/EFFECTIVITY
CH.4PTER
SECTIO\
SC BJECT
-
70-00-00
SUBJECT
-
--
STALDARD PRACTICES
- EYGINE
GRID
30.
2117
EFFECTIi'IT)
A 5-80
70 - Cont./Effec.
Page 1
Revised: August l I . 1983
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE M A N U A L
-
S T A N D A R D PRACTICES ENGINE.
The following suggestions should be applied wherever they are needed when working on the power plant.
I. T o insure proper reinstallation and - or assembly. tag and mark all pans. clips. and brackets as to their
location prior to their removal and . o r disassembly.
2. During removal of various tubes or engine pans. inspect them for indications of scoring. burning or
other undesirable conditions. T o facilitate reinstallation. observe the location of each part during removal.
Tag any unserviceable part and lor units for investigation and possible repair.
3. Extreme care must be taken t o prevent foreign matter from entering the engine. such as lockuire.
washers. nuts. dirt. dust. etc; This precaution applies whenever work is done on the engine. either on or off the
aircraft. Suitable protective caps. plugs. and covers must be used to protect all openings as they are exposed.
Dust caps used to protect open lines must always be installed 0 VER
the tube ends and NOT IN the tube ends. Flow through the lines may
be blocked off if lines are inadvertently installed with dust caps in the
tube ends.
4. Should any items be dropped into the engine. the assembly process must stop and the item must be
removed. e\.en though this may require considerable time and labor. Insure that all pans are thoroughl! clean
before assembling.
5 . Never reuse any lockwire. lockwashers. tablocks. tabwashers or cotter pins. All lockuire and cottcr
pins must fit snugly in holes drilled in studs and bolts for locking purposes. Cotter pins should be installed so
the head fits into the castellation of the nut. and unless otherwise specified. bend one end of the pin back o\.er
the stud or bolt and the other end down flat against the nut. Use only corrosion resistant steel lockmire and or
cotter pins. Bushing plugs shall be lockwired to the assembly base or case. Do not lockwire the plug to the
bushing.
6. All gaskets. packings and rubber pans must be replaced with new items of the same type at
reassembly. lnsure the new nonmetallic parts being installed show no sign of having deteriorated in storage.
7 . When installing engine pans which require the use of a hammer to facilitateassembly or installation.
use only a plastic or rawhide hammer.
8. Anti-seize lubrication should be applied to all loose-fit spline drives n.hich are external to the engine
and ha\,e no other means of lubrication. For certain assembly procedures. molybdenum disulfide in either
paste or powdered form mixed with engine oil or grease may be used.
-- CAUTION
-
Ensure that Anti-seize compounds are applied in thin even coats,
and that excess compound is completely removed to avoid
contamination of adjacent parts.
9. Temporary marking methods are those markings which will ensure identification during ordinary
handling. storage and final assembly of parts.
- END -
Page 70-01
Added:
Ma! 21. 1980
a
CHAPTER
POWER PLANT
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHAPTER 71
- POWERPLANT
TABLE O F CONTENTS/EFFECTIVITY
CH.4PTER
SECTIO\
SL'BJECT
GRID
SUBJECT
N 0.
EFFECTIL'ITI'
GESERAL
Description
Troubleshooting
Removal lnstallation Procedures
Rernoial of Engine (PA-32-301)
Rernoi al of Engine (PA-32-30 1 T)
Installation of Engine (PA-32-301 )
Installation of Engine (PA-32-301T)
COH'LIKG
Rernoial Installation Procedures
Rernoi al of COWling (PA-32-30 1 )
Installation of Cou.ling (PA-32-30 1 )
Rernoi.al and Installation of Cowling (PA-32-301 T)
Maintenance of Cowling
Clean~ng.Inspection and Repair of Cowling
71
- Cont./Effec.
Page - 1
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32.301 /301 T
MAINTENANCE MANUAL
GEKERAL.
DESCRIPTION.
The PA-32-301 is powered by a Lycoming engine of 300 horsepower. (Refer to Power Plant
Specifications in Chapter 6.) The engine is furnished with a starter. 60 ampere. 12-volt alternator. voltage
regulator. shielded ignition system. vacuum pump drive, fuel pump. fuel injector and a dry paper type
induction air filter. In the event of air stoppage through the filter an alternate air source can be opened when
selected manually by the use of a lever in the cockpit.
The exhaust system consists of three individual mufflers combined into one unit. Each set of opposing
cylinders feeds into one muffler. A heat shroud encircles the complete unit to provide heat for both the cabin
and defrosting.
The engine is provided with a constant speed propeller controlled by a governor mounted on the engine
supplying oil through the propeller shaft at various pressures.
The PA-32-301T is powered by a Lycoming engine model T10-540-SIAD. This engine is a direct drive.
six cylinder. fuel injected. horizontally opposed. air cooled engine with top side exhaust incorporating oil jets
for internal piston cooling. The engine is furnished with a starter. 60 amperes. 12-volt alternator. voltage
regulator. shielded ignition system vacuum pump drive. fuel injector and a dry paper type induction filter. In
the event of air stoppage through the filteranalternateair sourcecan be opened when selected manually by the
use of a lever in the cockpit. An automatic alternate air door is also provided on the induction tube
downstream from the blower.
The turbocharged engine develops 300 horsepower at 2700 rpm and 36 inches of mercury manifold
pressure at take-off for a maximum 5 minute limit. Maximum continuous power rating is 270 horsepower at
2575 rpm and 33 inches of mercury manifold pressure to an altitude of approximately 15.000 feet. The
turbocharger-blower has an integral overboost safety valve. Output is controlled by an interconnected control
between the injector throttle arm and the wastegate control a m . This mechanically programmed interconnect
eliminates a separate wastegate control lever.
The engine is provided with a constant speed-propeller controlled by a governor mounted on the engine
supplying oil through the propeller shaft at various pressures.
TROCBLESHOOTINC.
Troubles peculiar to the power plant are listed in Chart 7101 along with their probable causes and
suggested remedies. When troubleshooting the engine, ground the magneto primary circuit before performing
any checks of the engine.
7 1-00-02
Page 71-01
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 / 301 T
MAINTENANCE MANUAL
CHART 7101. TROUBLESHOOTING (ENGINE)
Cause
Trouble
Failure of engine to
start.
Remedy
Lack of fuel.
Check fuel system for
leaks. Fill fuel tank.
Clean dirty lines. strainers or fuel valves.
Check fuel selector valve
for proper tank.
Check fuel pressure with
electric boost pump 05.
Check mixture control
knob for full rich.
Overpriming.
Open throttle and "unload"
engine by engaging
starter. Mixture in
idle cut-off.
Incorrect throttle
setting.
Open throttle to oneeighth of its range.
Defective spark plugs.
Clean and adjust or
replace spark plugs.
Defective ignition wire.
Check with electric tester
and replace defective
wires.
Defective battery.
Replace with charged
battery.
Improper operation of
magneto breaker.
Clean points. Check
internal timing of
magnetos.
Lack of sufficient fuel
flow.
Disconnect fuel line at
fuel injector and check
fuel flow.
Water in fuel injector.
Drain fuel injector and
fuel lines.
J
71-00-02
Page 71-02
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 7101. TROUBLESHOOTING (ENGINE) (cont)
Trouble
Cause
Remedy
Failure of engine to
stan. (cont)
Internal failure.
Check oil screens for
metal panicles. If
found. complete overhaul of engine may be
indicated.
Failure of engine to
idle properly.
Incorrect idle mixture.
-.
Adjust mixture.
Leak in the induction
system.
Tighten all connections
in the induction system. Replace any pans
that are defective.
Incorrect idle adjustment.
Adjust throttle stop to
obtain correct idle.
Uneven cylinder compression.
Check condition of piston rings and valve
seats.
Faulty ignition system.
Check entire ignition
system.
Insufficient fuel pressure.
Adjust fuel pressure.
Mixture too rich: indicated by sluggish engine operation. red exhaust flame at night.
Extreme cases 'indicated by black smoke
from exhaust.
Readjustment of fuel injector by authorized
personnel is indicated.
Lower power and uneven
running.
71-00-02
Page 71-03
Issued: January 2,1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
C H A R T 7 101. TROUBLESHOOTING (ENGIKE) (cont)
Trouble
Lou power and u n e ~ e n
runnlng. (cont)
Failure of englne to
d e ~ e l o pfull power.
Cause
Remedy
Mixture too lean; indicated by overheating
or backfiring.
Check fuel lines for
dirt o r other restrictions. Check fuel injection nozzles.
Leaks in induction
system.
Tighten all connections
Replace defecth e
pans.
Defective spark plugs.
Clean and gap o r replace spark plugs.
Improper fuel.
Fill tank with fuel of
recommended grade.
Magneto breaker points
not working properly.
Clean points. Check
internal t i m ~ n gof magnetos.
Defective ignition wire.
Check wire with electric
tester. Replace defect~vewlre.
Defective spark plug
terminal connectors.
Replace connectors on
spark plug wire.
Leak in the induction
system.
T ~ g h t e nall connections
and replace defectne
parts.
Throttle lever out of
adjustment.
Adjust throttle l e ~ e r .
Improper fuel flow.
Check strainer. gauge
and flow at fuel Injector inlet.
71-00-02
Page 71-01
Issued: ~ a n u a r 2,
y 1980
PIPER AIRCRAFT
PA-32-301/ 301T
MAINTENANCE MANUAL
C H A R T 7 10 1. TROUBLESHOOTING (EKGIKE) (cont)
Trouble
Failure of engine to
debelop full pow,er.
(cont)
Rough engine.
Low oil pressure.
Cause
Remedy
Restriction in air scoop.
Examine air scoop and
remove restrictions.
Improper fuel.
Drain and refill tank
with recommended
fuel.
Faulty ignition.
Tighten all connections.
Check system with
tester. Check ignition
timing.
Cracked engine mount.
Replace or repair
mount.
Defective mounting
bushings.
Install new mounting
bushings.
Uneven compression.
Check compression.
Insufficient oil.
Fill sump with recornmended oil.
Air lock or d i n in relief valve.
Remove and clean oil
pressure relief v a l e.
~
Leak in suction line or
pressure line.
Check gasket between
accessory housing and
crankcase.
Dirty oil strainers.
Remove and clean oil
strainers.
Defective pressure
gauge.
Replace gauge.
-
Page 7 1-05
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 I301 T
MAINTENANCE MANUAL
C H A R T 7 101. TROUBLESHOOTING (EIVGIKE) (cont)
Cause
Stoppage in oil pump
intake passage.
I
Remedy
Check line for obstruction. Clean suction
High oil temperature.
See "High Oil Temperature" in "Trouble"
column.
Insufficient air cooling.
Check air inlet and outlet for deformation or
obstruction.
Insufficient oil supply.
Fill oil sump to proper
level with specified oil.
Low grade of oil.
Replace with oil conforming to specifications.
Clogged oil lines or
strainers.
Remove and clean oil
strainers.
Excessive blow-by.
Usually caused by worn
o r stuck rings.
Failing o r failed
bearing.
Examine sump for
metal particles. I f
found. overhaul of engine is indicated.
Defective temperature
gauge.
Replace gauge.
Low grade of oil.
Fill tank with oil conforming t o specifications.
251
71-00-02
Page 71-06
Issued: ~ a n u n r y 2 ,1980
I
I
PIPER AIRCRAFT
PA-32-301/ 301T
MAINTENANCE MANUAL
CHART 7101. TROUBLESHOOTING (EKGINE) (cont)
Trouble
Excessive oil consumption. (cont)
Cause
Remedy
Failing or failed bearings.
Check sump for metal
panicles.
Worn piston rings.
Install new rings.
Incorrect installation of
piston rings.
Install new rings.
Failure of rings to seat
(new nitrided cylinders).
Use mineral base oil.
Climb to cruise altitude at full power and
operate at 75% cruise
power setting with h ~ g h
oil temperature until
oil consumption stabilizes.
>
71-00-02
Page 71-07
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
A MAXIMUM OF (31AN960-616
WASHERS CAN BE USED TO
PERMIT A MAXIMUM OF 3
THREADS EXWSED ON THE
BOLT. TORQUE TO 230/240
INCH-POUNDS
n
SECTION A-A
TORQUE TO
450-500 IN. LBS
PA-32-301 AIRCRAFT
AND UP
LORD 9613-12 MOUNTING KIT
1
2.
3
4
5.
6
7
SPINNER
PROPELLER
FUEL FLOW DIVIDER
OIL FILLER
OIL COOLER. RIGHT
OIL COOLER. LEFT
VENTTUBE
8
9.
10.
11
12.
13.
14
STARTER
GOVERNOR
FUEL NOZZLE
ENGINE MOUNT
VALVE. OIL DRAIN
WASHER (J-2218-61)
SANDWICH (J-9612-8)
14
LORD 961 3-1 9 MOUNTING KIT
15.
16.
17.
18.
19.
20.
21.
SANDWICH (J-7763-1)
BOLT, NUT. WASHER
SANDWICH (J3W9.38)
SPACER (J-12333-2)
ENGINE MOUNT
PLUG
SANDWICH (J-3049-35)
22
23.
24
25.
26
ENGINE
MOUNTlNG KIT (J-3804-31)
SPACER (J-7766-9)
SPACER (J-7766-2)
ENGINE MOUNT
Figure 7 1 - 1 . Engine Installation (PA-32-30 1 )
71-00-02
Page 71-08
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
8S17
ENGINE MOUNT
I
ORIENT HEAT SHIELD SO
THAT B O l l O M EDGES
ARE PARALLEL TO FWD
UPPER H O R I Z O N T A L
ENGINE MOUNT TUBE
CLUO (UCCCII M W M S ONL
Y-6769-1 -S SPACER
(PART OF J-3804-40
J-12333.2 SPACER
(PART OF J-3804-31 my
NOTES
-
MEW A
J-3-4
MOUNTING KIT'
J-3804-31 MOUNTING KIT'
J-3049-66 SANDWICH (PART OF J-3804-40 KIT)'
J-3-9-35
SANDWICH (PART OF J-3800-31 KlTP
Figure 7 1-2. Engine Mount Installation (PA-32-30 1 T) (Dynafocal)
71-00-02
Page 71-09
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
1
ORIENT HEAT SHIELDS SO THAT TOP
EDGES ARE PARALLEL WITH FWD UPPER
HORIZONTAL ENGINE MOUNT TeJBE
,230
-- ENGINE MOUNT
TUBE
f
L'--EXHAUST PlPE
ISOUTER
EXHAUST PlPE
ISOMER
,
-
HEAT SHIEUI ASSEMBLY (UPPER
MOUNTS ONLY)
FWD
PLUG (UPPER MOUNTS ONLY)
ENGINE MOUNT
BOLT. WASHERS. AND NUT
(INSTALL BOLT PER PPS-20015)
J9613-55 ISOUTER (UPPER MOUNT ONLY)
J-9612-31 ISOUTER
J-10931-5 SPACER
PART OF
J-7763-35 ISOUTER J-961 3-55 KIT
WASHER
SEE NOTE
BOLT. WASHERS AND NUT
LOWER MOUNT
.
(INSTALL BOLT PER PPS-20015)
l
.
ENGINE MOUNT
NOTE
REQUIRE 1 THREAD MIN 3
THREADS M A X EXPOSE
PAST NUT USE AN 960-71 6
OR -716LAS NECESSARYTO
ATTAIN PROPER CLEARANCE
J-9613-19 ISOUTER KIT (LOWER MOUNT ONLY)
J-7763-1 ISOUTER
OF
J-7766-2 'qACER j.961 3-19 KIT
J-9612-8 ISOUTER
Figure 71-3. Engine Mount Installation (PA-32-3OIT) (Lord Mounts)
71-00-02
Page 71-10
Added: September 23, 1981
PIPER AIRCRAFT
PA-32-301 / 3 0 l T
MAINTENANCE M A N U A L
I . Turn 01.1 1111 tlrctrical r\\itchcs in the cockpit and then disconnect the hatter! ground u i r c at thc
h:~ttcr!.
2 . Arcenain that the fuel \elector le\ e r is in the "OFF" position.
3. R e m o \ c the propeller. (Refer t o Chapter 61 . I
4 . Di\connect the starter po$iti\e and ground leads at the injector. ( T h e in,iector ma! he remmcd 11
derired.)
5 . Di\conncct the go\ernor control cable a t the go\.ernor and cable attachment c l a m p .
6 . Disconnect the heater ho5e at the muffler.
7 . Di\connect the throttle and mixture cables at the injector. (The injector ma! be remo\ed if derircd. I
.
Dlrconnect [he fuel pump suppl!. line a t the left side of the pump. Disconnect pump \cnt linc
- NOTE W'here a question may arise as where to reconnect a hose. line or
nlire; the item at the separation should be identi/ed (tagged) to
facilitate reinstallation. Fuel, oil. vacuum lines and fittings should
be covered immediately upon separation to prevent contamination.
9.
I .
II
I2
17
14.
15.
Ih
17.
IK
10.
2
I
mount>.
Dirconnect hoth lines from each oil cooler at the coolers.
D~rconnectthe magneto "P" leads at the magnetos.
D ~ \ c o n n e cthe
~ engine \en1 tube at the engine.
Dirconnect the engine oil temperature lead a t the aft end of the engine.
D~*;connectthe tachometer d r i \ e cable at the engine.
I'ntie the ignition harness hoses and lines at the aft of the engine.
Dirconnect the lcrcuum pump line\ at pump and remo\.e fittings from pump.
D~yconnectthe oil pressure line at the engine.
Dirconnect the static and fuel flow line at the right rear engine baffle.
Dirconnect the manifold preYrure line at the right rear side of the engine.
Dirconnect the iniector line at the flow di\-ider.
Dikconnect the alternator leads and the cable attachment clamps.
.4tt;ich a one-half ton (minimum) hoist t o the hoisting straps and relie1.e the ten5ion from the snglnc
- WARNING Place a tail stand under the tail ojthe airplane before removing the
engine.
!
22. Check the engine for any attachments remaining t o obstruct its removal.
2.7 Drain the engine oil. if desired. and then close drain.
24. Remo\ c the four engine mount assemblies and s~ ing the engine free. heingcareful not to damagc ~ n !
attaching partr.
71 -00-04
Page 71-11
Revised: ~ u ~ u s t 1984
9.
PIPER AIRCRAFT
P.4-32-301/301
T
MAINTENANCE MANC'AL
R E M O V A L OF ENGIXE. (P.4-32-301T.)
1 . Turn off all electrical switches in the cockpit and then disconnect the batter! ground wire at the
hatter!.
2 A\cenain that the fuel selector le\er is in the "OFF" position.
3 Rerno\e the propeller. (Refer to Chapter 61.)
Where a question may arise as where to reconnect a hose. line or
wire: the item at the separation should be identified (tagged) to
facilitate reinstallation. Fuel, oil, vacuum lines and fittings should
be covered immediately upon separation to prevent contamination.
V a k e the following electrical disconnections:
A . Starter positi\.e and ground leads.
B. Alternator leads and the cable attachment clamps.
C . Magneto 'P" leads t o the magnetos.
D. Oil temperature. cylinder head temperature and exhaust gas temperature lead\.
5 Mechanical disconnections necessary for engine removal are as follou.+:
.A. Control cable at the propeller governor and cable attachment clamps.
B The throttle and mixture cables at the injector.
C. The tachometer dri\e cable at the engine.
6 . The folln\\ ing di\connections of en\.ironmental equipment are also necessary
.A. Heater and defroster hoses at the muffler.
B. .Air conditioning compressor lines.
7 . The following engine lines should also be disconnected.
.A. Manifold pressure line a t the right rear side of the engine.
B. Oil pressure line at the engine.
C . \'acuum pump lines at the pump.
D. Deck pressure and fuel flou lines at the engine baffle.
E . Fuel suppl!. line at the engine pump and pump drain tube.
F. Induction air inlet duct hose.
G . Oil breath tube from the engine mount.
H . Cooling ducts to \.acuum pump and fuel pump shroud.
I . Remo\e oil cooler support bracket.
J . Disconnect oil cooler at mounting bolts.
8 . .Attach a one-half ton (minimum) hoist t o the hoisting straps and relie\,e the tension from the engine
mounts.
4.
Place a tail stand under the tail of the airplane before removing the
engine.
9. Check the engine for any attachments remaining t o obstruct its rernoi-al.
10. Drain the engine oil. if desired. and then close drain.
I I . R e m o ~ the
e four engine mount assemblies and swing the engine free. being careful not t o damage an!
attaching parts.
7 1-00-05
Page 71-12
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
•
INSTALLATION O F ENGINE. (PA-32-301 .) (Refer t o Figure 71-1.)
-- CAUTION
-
Pre-oil an engine prior to initial start after an t n g k change,
overhaul or prolonged period of inactivity. This reduns the
possibility of high speed b w i n g jaihre resuhing from a lack of
lubrication. Refm to the lostest revision o j Lycoming Service
Instruction 1241.
I . Attach a one-half ton (minimum) hoist to the engine hoisting straps and swing the engine into
alignment with its attaching points.
2. Insert an engine mount bolt. with washer against head. in the engine mount and slide half of the
mount assembly on the bolt. (Refer to Figure 71-1 for proper shock mount assembly.) Repeat this procedure
for the other three attachment points.
-
NOTE
-
Shock mount Part No. J-3019-35 or 5-7763-1 sandwich must be
positioned on the compressionside ojthe engine lugs, with the upper
mounts on the forward side, and the lower mounts on the aft side.
The part number is stomped on the metalface of the mount. (Rejer
to Figure 71-1.)
3. Position the mounting lugs of the engine so that they align with the engine mount attachins point>.
then m0L.e the engine rearward onto the mounts.
4 . Slide onto each mounting bolt a spacer and the forward half of the mount. Install washer and nut. and
torque the nuts of the bolts to 450 to 500 inch-pounds.
5 . Connect the alternator leads and secure cable with clamps.
6 Connect the injector line to the flow divider.
7 . Connect the manifold pressure line at the right rear side of the engine.
P. Connect the static and fuel flow line at the right rear engine baffle.
9 . Connect the oil pressure line.
10. Install the line fitting in the vacuum pump and install lines.
I I . Connect the tachometer drive cable.
12. Connect the oil temperature lead.
17. Connect the engine vent tube.
13. Connect the oil cooler lines t o each oil cooler.
IS. Connect the magneto "P" leads. Check that magneto switch is "OFF."
I
Connect the fuel pump supply and vent line.
17. Install the injector.
18. Connect the throttle and mixture cables t o the injector. Check adjustment of the control.
19. Connect the heater hose t o the muffler.
20. Check adjustment of the alternate air door.
2
Connect the governor control cable and secure with clamps.
2 . Connect the starter positive and ground leads and secure cables with clamps.
2 . Secure the ignition harness. lines. hoses. wires. etc. that may be loose.
7 1-00-06
Page 71-13
Revised: August 9. 1984
P I P E R AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANLTAL
ISST.ALLATIO\ OF ENGISE. (P.4-32-301T.) (Refer t o Figures 71-2. 71-3.)
- CA
b'TI0.Y
-
Pre-oil an engine prior to initial start after an engine change.
ot.erhaul or prolonged period of inactivity. This reduces the
possibility of high speed bearing failure resulting from a lack of
lubrication. Refer to the latest revision of Lycoming Service
Instruction 1241.
I . .4tt;1ch a one-half ton (minimum) hoist to the engine hoisting straps and suing thc clnginr' Into
alignment u ith i t 3 attaching points.
2 . Insert a n engine mount holt. with washer against head. in the engine mount and slide hitlf 01' rhc
mount assemhl! on the holt. (Refer t o Figures 71-2. 71-3 for proper shock mount assembl! . l Rcpcat [hi.
procedurc for the other three attachment points.
-NOTE Lpper mounts also have a heat shield assembb which must be
installed with the engine mounts. Rotate shield assemb!~to provide
maximum protection against exhaust heat.
Po4ition the rnounting lugs of the engine s o that they align with the engine mount ~ i t t i ~ c h ~point*.
ng
.
then m o \ e the engine r e a w a r d onto the mounts.
4
Slide o n t o each rnounting bolt a spacer and the foru.ard half of the mount. Install u a s h r r and nut. ;lnJ
toiuucl the nut, of the bolts to 450 to 500 inch-pounds.
5 ln\taIl propeller (Refer to Chapter 61 . )
6 . \lahe the follouing electrical connections:
.4. The starter positi\e and ground leads and secure cablec w.ith clamps.
R . The ;\Iternator leads and secure cable u.it h clamps.
C. The magneto "P" leads. Check that magneto suitch i \ "OFF."
D. Oil temperature. cylinder head temperature and exhaust gas temperature lead\.
7
Mechanical connections necessar!. for engine installation are as follou,:
.A. G o \ e r n o r control cable and secure with clamps.
B. T h e throttle and mixture cables t o the injector. Check adiustment of the control.
C . Connectthe tachometer dri\.e cable.
The follouing connections of en\.ironmental equipment are also necessar):
%
A . Hcater and defroster hoses at the muffler.
R. .Air conditioning compressor lines (Refer to Chapter 21).
9. The follo\t.ing engine lines should also be connected.
4 . hlanifold pressure line a t the right rear side of the engine.
B. Oil prewure line at the engine.
C. i'acuum p u m p lines at the pump.
D. Deck pressure and fuel flow lines at the engine baffle.
E . Fuel suppl!. line at the engine pump and pump drain tube.
F. Induction air inlet hose.
G . Oil breath tube t o the engine mount.
H . Check the engine for any connections remaining.
I . Install the proper grade and amount of engine oil.
J . Connect cooling ducts t o i a c u u m pump and fuel pump shroud.
10. Turn on fuel \ a I \ e : open throttle full and turn on theelectrical fuel pump.and check the fuel Iinr'si~nd
fitting.; for leak..
7 1-00-07
Page 71-14
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32301 / M l T
MAINTENANCE MANUAL
I I . Install engine cowling in the reverse order of removal (Refer t o Remo\,al and Installation of Engine
Cokrling PA-32-3OIT). Connect the electrical lead t o the landing light.
I . Perform an engine operational check.
COWLING.
1
REMO\'AL/INSTALLATION PROCEDURES.
REMOVAL OF COWLING. (PA-32-301 .)
I . Release the cowl fasteners. two on each side and two at the top aft of the c o u l .
2 . Lift the aft end o f the cowl and then slide it forward to release the two stud type front fa>tenc.r>.
Rern0k.e the top c0u.I.
3. Disconnect the landing light lead at the quick disconnect at the right rear side of the bottom co\\I.
4. Remo\e the induction air filter access cover. the filter and four bolts which hold the air bo\ to the
cow 1.
5 . Remo\e the nose gear strut fairing (if installed).
6 . Support the cowl and remo1.e the screws securing the bottom cowl to the engine mount landing _re.lr
st rut assembl!.
7. Remo\e the screws securing the bottom cowl to the fuselage firewall flange and remo\,e the hottom
cow 1.
Position the bottom cowl and secure in place with screws along aft end of cowl and at engine
landing gear strut assembly.
Connect the air box t o the c o u l with four bolts. install filter and secure access toter.
Connect the electrical lead to the landing light.
3. Install the upper cowling.
I.
mount
2.
3.
REMOVAL A N D INSTALLATION O F COWLING. (PA-32-301T.)
Release the upper cowl stud fasteners. a t the forward and aft end of the cowl.
Release the side latches. two each side.
Remoke the upper cowl by lifting straight up to clear the positioning studs and latch e!.ebolts.
Remole the screws attaching the nose cowl t o the bottom cowl.
Disconnect the landing light lead at the quick disconnect just behind the light.
Rern0k.e the nose gear strut fairing (if installed).
R e m o ~ ethe cowl louver assemblies and the nose gear cover assembly.
Support the cowl and remove the screws which secure the bottom cowl to the fuselage fireu.all flange.
Install cowling in reverse order of removal.
7 1-10-04
Page 71-15
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANC'AL
CI.EAAIAC,. I U S P E C T I O S A S D R E P A I R OF
COWLING.
Clc..~nco\\ I ~ n g\I ~ r ha 4ultahle cleaning s o h e n t and wlpe dr! with 3 clean cloth
Inbpcct cn\{l~ngfor dent\. crack\. loo4e ri\ct\. elongated holes and damaged or rn1441ngI,~\tcncr\
! R c p a ~ rall dr.fcct\ t o prcient further damage
I
2
- END -
71-10-06
Page 71-16
Revised: August 9 . 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MAKUAL
THIS P A G E INTESTIOIVALLY LEFT BLAIVK
PIPER .AIRCR.AFT
P.4-32-301/301 T
\I.I\ISTEXxSCE S I A S L . 4 L
T H I S P.ACE I \ T E S T I O S A L L I ' L E F T B L A S K
CHAPTER
ENGINE FUEL SYSTEM
PIPER AIRCRAFT
PA-32-30 11301 T
MAINTENANCE MANUAL
CHAPTER 73 - ENGINE FUEL SYSTEM
TABLE O F CONTESTS/EFFECTIVITY
CH.4PTER
SECTIOX
SUBJECT
SUBJECT
GRID
NO.
EFFECTI\'ITI'
GEKERAL
DISTRI BCTION
Fuel Injector System
Fuel Injector Maintenance
Fuel- Air Bleed \ ozzle ( PA-32-30 I )
Removal of Fuel-Air Bleed Sozzle ( PA-32-301 )
Cleaning and Inspection of Fuel-Air Bleed Sozzle
( PA-32-30 I )
Fuel-Air Bleed Sozzle ( PA-32-30 1 T)
R e m o ~ a lof Fuel-Air Bleed Nozzle (PA-32-30 IT)
Clcaninp and Inspection of Fuel-Air Bleed Nozzle
( PA-32-30 I T )
Installation of Fuel-Air Bleed h'ozzle ( PA-32-30 1 T)
Adjustment of Idle Speed and Mixture
COKTROLLIKG
Adjustment of Throttle and Mixture Controls
-
73 Cont./Effec.
Page - 1
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GENERAL.
I FI'El. ISJECTOR
The Bendix RSA type fuel injection system is based on the principle of measuring air flow and u\ing thc
air flow signal in a stem t!.pe regulator t o convert the air force into a fuel force. This fuel force (fuel pres5ure
differential) when applied across the fuel metering section (jetting system) makes fuel flow proportional t o alr
flow. Fuel ~ a p o r i ~ a t i otakes
n
place a t the intake ports.
FI'EL ISJECTOR MAINTENANCE.
I . In general. little attenti0n.k required between injector overhauls. Howe\er. it is recommended rhiir
the follou ing items be checked during periodic inspection of the engine:
.A. Check tightness and lock of all nuts and screws which fasten the injector t o theengine. torquing
311 nuts t o 135-150 inch-pounds.
B. Seat the pal t!.pe locknuts and finger tighten them against the plain nuts. After this ha5 heen done
tighten the locknuts an additional 1 3 to 1 2 turn.
C . Check all fuel lines for tightness a n d evidence of leakage. A slight fuel stain adJacent 1 0 rhr air
bleed no77les is not cause for concern.
D. Check throttle and mixture control rod ends and levers for tightness and lock.
E . Remoie and clean the injector inlet strainer a t the first 25 hours of operation and each 50 hour
inspection thereafter. Check the screen for distortion o r o p e n i n g in the strainer. Replace.for either of t h e e
conditions. Clean screen assembly in solvent and dry with compressed air. Damaged strainer O-ring\ 4hould
he replaced. T o install the screen assembl!.. place the gasket on the screen assembly and install the asscmbl! in
the throttle bod!. and tighten t o 35-40 inch-pounds torque.
F1'EL-AIR BLEED NOZZLE. (PA-32-301 . )
REMOVAL OF FUEL-AIR BLEED NOZZLE. (PA-32-301.)
T h e no77les must be carefully removed as they or the cylinders may be damaged
I . Remo\e the lower engine cow I.
2. Disconnect the fuel line from the nozzle.
3. Carefull> rerno\e the nozzle. using the correct size deep socket.
4. Clean and inspect the noztle as given in the next paragraph.
Page 73-01
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
C L E A S I S G A S D ISSPECTION O F FI'EL-AIR BLEED NOZZLE. (PA-32-30 I . )
I . Clean the no77le \\ith acetone o r equivalent and blow out all foreign particle5 ~ i t compre\sed
h
air in
the direction oppo\ite that of fuel flow. D o not use wire or other hard objects to clean orifices. (Refer to latest
re\i\ion nf L\coming S e n i c e Instruction No. 1275.)
2 . In4pec1 the no77le and c!,linder threads for nicks. stripping o r cross-threading.
1. In4pect for battered or rounded hexagons.
1. .4 t e ~ procedure
t
for air bleed norzles is described in latest re\.ision of Lycoming Ser\ ice Instrucrion
KO.
Fl'EL-AIR BLEED NOZZLE. (PA-32-3OIT)
REMOk'AL OF FC'EL-AIR BLEED KOZZLE. (PA-32-3OIT.)
The n o n l e s mu\[ be carefull) remoted as they o r the cylinders may be damaged.
I . R e m o \ e the lou.er engine cow I.
2. Dihconnect the fuel line from the nor7le.
R e m o i e the spring retainer and spring from the nozsle stem.
.
4. Disconnect the no77le shroud from the \ent hose and remove it from the no77le
5 . Careiull! remo\ e the n o u l e . using the correct size deep socket.
C L E A S I N C A N D INSPECTION O F FL'EL-AIR BLEED NOZZLE. ( PA-32-30 1 T.)
I . Clean the no77le with acetone o r equkalent and blow out all foreign particles. D o not use u i r e or
ot her hard obiects to clean orifices. (Refer to latest re\.ision of Lycoming S e n i c e Instruction \ o . 12'5.1
2. In\pect and replace no77le O-rings if found t o be cracked. brittle or distorted.
3. . test procedure for air bleed n o n l e s i5 described in the latest revision of L!coming S e n i c e
In*truction Ko. 1275.
INSTALLATIOS OF Fl'EL-AIR BLEED NOZZLE. (PA-32-301T.)
1.
It
I<
important for the n o n l e s to be correctly positioned with the bleed hole upward.
- CA UTION Start nozzles and line couplings by hand toprevent thepossibility of
cross-threading.
2. In\tall the no77les and torque t o 60 inch-pounds.
3 A\certain that the O-rings are properly i n s ~ l l e don the nozzle stem and install the noz7le shroud.
(Refer to Figure 73-3.)
4. Connect the \ent to the norzle shroud.
5 . Install the spring and spring retainer on the nozzle stem.
6 . Connect the fuel line to the noz7le and clamp the fuel lines a s described in latest re\ ision of L! coming
S e n ice Bulletin S o . 335.
7. Install the engine cowl.
7s 10-09
Page 73-02
Revised: August 9. 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
.
7. WAOTE-OAT'E INTERCONNECT
-
Figure 73-1. Fuel Injector
-
THIS SPACE INTENTIONALLY LEFT BLANK
73-10-09
Page 73-02
Revised: August 9. 1984
I
.
PIPER AIRCRAFT
PA-32-30]1301T
'MAINTENANCE MANUAL
NOZZLE
(ONE PER CYLINDER)
' I
I
I
I
--
. . - .'
.;.r--
I .
4
FUEL INLET
FUEL STRAINER
I
I 10-
I
I 1 8 INCH 0 D STAINLESS
S T E E L LINE
I
/
I
I
I
I
I
I
I
I
I
I
I
I
I
'
I
I
L
---- - - -
---
-,,
,,--_
9 , ,
\------,
II
I
I
II
11
II
I
SECT I O N
I
-a
I
II
II
IDLE VALVE L E V E R
CONNECT ED TO
THROTTLE L E V E R
LINKAGE
I
ROTTLE VALVE
I
I
I
THR JTTLE LEVER
.
I
!I
I
i
AIR DIAPHRAGM
FUEL DIAPHRAGM
BALL SERVO VALVE
/'
I
I
Figure. 7 3 - 2 . Schematic Diagram of R S A Fuel lniection S ~ s t e m
73-10-09
Page 73-04
Revised: .August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ADJUSTMENT OF IDLE SPEED AND MIXTURE.
1 . S t a n the engine and warm up in the usual manner until oil and cylinder head temperatures are
normal.
2. Check magnetos. If the "magdrop" is normal, proceed with idle adjustment.
3. Set throttle stop screw so that the engine idlesat 550-600 RPM. If the RPM changes appreciably after
making the mixture adjustment during the succeeding steps, readjust the idle speed to the desired RPM.
4. When the idling speed has been stabilized, move the cockpit mixture control lever with a smooth.
steady pull toward the "Idle Cut-Off" position and observe the tachometer for any change during the leaning
process. Caution must be exercised to return the mixture control to the "Full Rich" position before the RPM
can drop to a point where the engine cuts out. An increase of more than 10 RPM while "leaning out"indicates
a n excessively rich idle mixture. An immediate decrease in RPM (if not preceded by a momentary increase)
indicates the idle mixture is too lean.
5. If the above indicates that the idle adjustment is too rich ortoo lean, turn the idle mixtureadjustment
in the direction required for correction. and check this new position by repeating the above procedure. Make
additional adjustments as necessary until a check results in a momentary pick-up of approximately 5 (never
more than 10) RPM. Each time the adjustment is changed, the engine should be run up to 2000 RPM to clear
the engine before proceeding with the RPM check. Make final adjustment of the idle speed adjustment to
obtain the desired idling RPM with closed throttle. The above method aims at a setting that will obtain
maximum RPM with minimum manifold pressure. In case the setting does not remain stable. check the idle
linkage: any looseness in this linkage would cause erratic idling. In all cases. allowance should be made for the
effect of weather conditions and field altitude upon idling adjustment.
CONTROLLING.
ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS. (Refer to Figure 734.)
Throttle and mixture controls are adjusted so that when the throttle arm on the fuel injector is rotated
forward against its full throttle stop and the mixture control is rotated forward against its full rich stop. the
cockpit control levers of the throttle and mixture should have 0.010 to 0.030 of an inch spring back on
instrument panel stop when in full throttle or full rich position.
1. The throttle may be adjusted as follows:
A. At the fuel injector, disconnect the clevis end of the throttle control cable from the control arm.
Loosen the jam nut that secures the clevis end.
B. Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an inch
spring back on instrument panel stop when in full throttle position.
C. On aircraft equipped with air conditioning systems, a micro switch is located below the throttle
control which is set to actuate in the full open position. With the throttle adjusted to obtain a clearance of .0 10
to .030, adjust the micro switch to actuate a t this point also.
D. Reconnect the clevis end to the control arm and safety.
Page 73-05
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
-
222
1. R m A I N E R
2. SPRING
3. CAP
4 . "0" R I N G
5. "0"RINQ
6. N O Z Z L E
-
Figure 73-3. Fuel Air Bleed Nozzle
Figure 73-4. Adjustment of Engine Controls
73-20-01
Page 73-06
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-3611301T
MAINTENANCE MANUAL
2. The mixture may be adjusted as follows:
A. At the fuel injector. disconnect the clevis end of the mixture control cable from the control arm.
Loosen the jam nut that secures the clevis end.
B. Adjust the linkage by rotating the clevis end on the cable to obtain 0.010 to 0.030 of an inch
spring back on the instrument panel stop when in full rich position.
C. Reconnect the clevis end to the control arm and safety.
3. Check security of cable casing attachments.
4. Pull the throttle and mixture levers in the cockpit full aft to ascertain that the idle screw contacts its
stop and the mixture control arm contacts its lean position. A mixture control lock is incorporated in the
quadrant cover which prevents the mixture control from being moved to the idle cutoff position inadvertently.
The lock must be depressed before the control can be moved completely aft. Ascertain that the lock operates
freely without any tendency to bind or hang up.
- END -
Page 13-07
Issued: January 2, 1980
I
.
CHAPTER
IGNITION
PIPER AIRCRAFT
PA-32-30 11301T
MAINTENANCE MANUAL
-
CHAPTER 74 IGNITION
TABLE O F CONTENTSIEFFECTIVITY
CH 4PTER
SECTIO\
SUBJECT
SUBJECT
GRID
\ 0.
EFFECTIC'IT'\'
GEYERAL
Description and Operation
Troubleshooting
ELECTRICAL PON'ER SUPPLY
Magnetos
lnspection of Magneto
Magneto 1 nstallation and Timing Procedure (Timing
Magneto to Engine)
Magneto Timing Procedure (Internal Timing)
Impulse Coupling
Remolal of Impulse Coupling
lnspect~onof Impulse Coupling
Installation of Impulse Coupling
DISTRIBUTIOS
Harness
lnspection of Harness
hlaintenance of Harness
Spark Plugs
Rerno\al of Spark Plugs
lnspection and Cleaning of Spark Plugs
Installation of Spark Plugs
S\!'ITCHI\G
lgnition Suitch
Remo\,al of lgnition Switch
Installation of lgnition Switch
74 - Cont./Effec.
Page 1
Revised: August 9. 1984
-
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
GENERAL.
DESCRIPTION AND OPERATION.
The D-203 1 magnetos feature two electrically independent ignition circuits in one housing. A single four
pole rotor provides the magnetic energy for both circuits. This magneto uses an impulse coupling to provide
reliable ignition to engine cranking speed. A single cam operates the main breakers for both m a p e t o c~rcuits.
Suppression of contact point arching and conducted ratio interference is accomplished by feed-thru capacitors
which are mounted in the magneto cover which forms a p a n of the magneto harness assembly. At low engine
cranking speeds the impulse coupling automatically retards the magneto until the engine is also at its retard
firing position. The spring action of the impulse coupling is then released to spin the rotating magnet and
produce the spark required t o fire the engine. After the engine starts. the impulse coupling flyweights d o not
engage due to centrifugal action. The coupling then acts a s a straight drive and the magneto fires at the normal
firing position of the engine.
Ascertain that the primary circuits oj both magnetos are groun&d
before working on the engine.
TROUBLESHOOTING.
I
Troubles peculiar to the power plant's electrical system are listed in Chart 7401 along with their probable
cause and suggested remedies. When troubleshooting the engine, ground the magneto priman circuit before
performing any checks on the engine.
74-00.02
Pane 7 4 0 1
Revised: February 19, 1982
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL'
-
C H A R T 7401. TROUBLESHOOTIKG ( M A G K E T O )
Trouble
Cause
Remed:
Defective spark plugs.
Clean and adjust o r replace
spark plugs.
Defective ignition wire.
Check with electric tester and
replace defecti\.e wires.
Defective battery.
Replace with charged batter!..
Improper operation of
magneto breaker.
Check points. Check internal
timing of magnetos.
Failure of engine to idle
properly.
Faulty ignition system.
Check entire ignition system.
Lou pow.er and une\-en
running.
Defecti\e spark plugs.
Clean and gap or replace
spark plugs.
Magneto breaker points not
working properly.
Clean points. Check internal
timing of magnetos.
Defective ignition wire.
Check wire with electric
tester. Replace defectl\e uire.
Defective spark plug terminal connectors.
Replace connectors on spark
plug wire.
Faulty ignition.
Tighten all connections.
Check system u i t h tester.
Check ignition timing.
Failure of englne to start.
Failure of engine to
d e ~ e l o pfull pouer.
74-00-02
Page 74-02
Issued: ~anuarj-2.1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ELECTRICAL POWER SUPPLY.
MAGNETOS.
INSPECTION O F MAGNETO.
After the first 50 hour period and every 100 hours thereafter. the magneto ignition system should be
checked. If engine operating troubles develop which appear t o be caused by the ignition system. it is ad\.isable
to check the spark plugs and wiring first before working on the magneto. Should trouble appear definite]!.
associated with the magneto. the most effective measure is t o install a replacement magneto which is known to
be in satisfactory condition and send the suspected unit to the overhaul shop for rest and repair. Should this
not be possible. a visual inspection of the following items may disclose the source of trouble.
1. Check the lead terminals for definite contact with spring contacts in outlets.
2. Remote the harness outlet cover from the magneto and inspect for the presence of moisture and
carbon tracking due to moisture.
3. Check contact springs in distributor block for evidence of spark erosion.
4. Check height of contact springs (0.422 maximum from top of block tower to spring). (Refer to Figure
74-2.)
5. With the co\,er and harness separated from the magneto housing. check contact assemblies to see that
cam follower is securely riveted to its spring.
6. Examine the contact points for excessive wear or burning. Figure 74-1 shows how the aterage contact
point mill look when surfaces are separated for inspection.
- CA UTION Do not open point contacts more than .0625 of an inch for
examination of contact surfaces.Excessive spreading of the breaker
points will overstress and damage the contact spring.
Desired contact surfaces have a dull gray. sand-blasted (almost rough) or frosted appearance. o\.er the
area where electrical contact is made. This means that points are worn in and mated to each other. thereb!.
pro\iding the best possible electrical contact and highest efficiency of performance. Minor irregularities or
roughness of point surfaces are not harmful. (Referto Figure 74-1. center.) hieither are small pits or mounds. if
not too pronounced. I f there is a possibility of pit becoming deep enough to penetrate pad (refer to Figure 74- 1 .
right). reject contact assembly.
-- NOTE
-
No attempt should be made to stone or &ess contact points. Should
contact assembly have bod points or show excessive wear, the
complete contact assembly should be replaced.
7. Check condition of cam follower felts for proper lubrication. If oil has migrated from one follower
felt to another. it may be necessary to remove the lubrication from one felt strip while oiling another. I f felt is
overlubricated. remove oil by using a clean, lintless cloth. If dry. apply one or two drops of Bendix Breaker Felt
Lubricant 10-86527.
74-10-02
Paee 74-03
issued: ~ r n u a r i 2 .1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 74-1. Height of Spring in Distributor Block Tower
NORMAL POINT I S SMOOTH
AND FLAT. SURFACE HAS
DULL GRAY "SANDBLASTED"
APPEARANCE
-
MINOR I R R E G U U R I T I E S
SMOOTH ROLLING H I L L S
AND DALES WITHOUT ANY
DEEP P I T S OR HIGH PEAKS.
THIS IS A NORMAL COND l T ION OF POINT WEAR.
WELL DEFINED MOUND
EXTENDING NOTICEABLY
ABOVE SURROUNDING
SURFACE. REJECT POINTS.
Figure 74-2. Contact Points
74-10-02
Page 74-04
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
8. Check the capacitors for looseness in the magneto cover of the harness assembly and for any ph! sical
damage. Using a Bendllv 1 I - 1767- 1. -2 or -3 condenser tester or equivalent. check capacitors for capacitance.
series resistance and leakage. Capacitance shall be 0.34 to 0.41 microfarads.
9. Check magneto to engine timing per instructions given in the following paragraph.
10. Check action of impulse coupling. With the ignition switch off. observe breaker cam end of rotor
while manually cranking the engine through a firing sequence. The rotor should alternately stop and then (uith
an audible snap) be rotated rapidly through a retard firing position. If impulseaction is not correct. remo\e the
magneto for okerhaul.
MAGNETO INSTALLATION A N D TIMING PROCEDURE. (Timing Magneto to Engine)
- WARNING Do not attach harness spark plug ends to the spark plugs until all
magneto to engine thing procedures and magneto to switch
connections are entirety completed.
The use of a timing light unit Part No. 11-9110 or 11-9110-1 will
simplify the timing procedure. This unit is availablefrom the Bendi.
Corporation at Sidney, New York 13838.
I . Remove the spark plug from the No. I cylinder and turn the crankshaft in the direction of normal
rotation until the compression stroke is reached.
2. Continue turning the crankshaft until the 20' advance timing mark is in alignment with the small hole
located on the top face of the starter housing at the two o'clock position. (Refer to F~gure74-1 )
3. The D-2000 series magneto may be mounted to the engine without removing the coier from the
magneto. The cover also has switch terminal outlets for the right and left sides of the magneto. located In the
center of the harness lead outlet section of the cover. (Refer to Figure 74-4.)
It is recommended that short adapter l&ds befabricated tofacilitate
connecting the thing light unit to the switch outlet terminals of the
cover. (Refer to Figure 74-4.)
4. The magneto incorporates a built-in pointer and a degree wheel with sufficient reference to assist the
mechanic in magneto timing procedures. Printed upon the rotating magnet are marks to indicate magneto
neutral and magneto "E"gap (8'). (Refer to Figure 74-5.) Also included are retard angle references of 10. 15. 20
and 25 degrees. These marks are set up for either clockwise ( R ) or counterclockwise (L) rotation of the
magneto as viewed from the magneto drive end. The timing tooth of each large distributor gear is marked u ith
red paint. (Refer to Figure 74-6.)
Page 74-05
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
C
A867
BENDIX smtcw LEA
TERMINAL K I T
*
Figure 74-4. Timing Light Connected t o Magneto
74-10-03
Page 74-06
Issued: Januar! 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
.
2101,
RETARD ANGLES
"E" GAP ANGLES
Figure 74-5. Timing Marks on Magneto Rotor
-- NOTE
-
A magneto, correctly timed internally, will hove the timing teeth of
the large distributor gears approximately centered in the timing
windows at each end ojthe magneto; the R'("EVgap)mark which is
closest to the "K"or keyway up position indicator on the rotor in
alignment with the pointer, and both main breaker points opening
aU at the same time. These three references, "EWgap,
painted teeth,
and point opening are all used when timing the magneto to the
engine.
5. Remove the magneto drive gear backlash by turnink the propeller opposite to normal rotation
approximately 40' past No. I firing position; then turn propeller in direction of normal rotation up to 30.1
firing position of 20' BTC.
6 . Remove the plug from the distributor inspection windows at either end of the magneto housing.
(Refer t o Figure 74-6.) Also remove the plug from the "E" gap inspection window on the data plate side of the
magneto housing. (Refer t o Figure 74-7.)
7. Turn the rotating magnet drive shaft in the normal direction of magneto rotation until the red
distributor tooth appears in the distributor inspection window. and also check to see if the letter "K"appears in
the "EWgapinspection window on the data plateside. If the letter "BS'is in the window. turn the magneto shaft I
I 2 times in the direction of rotation and check again to be sure the "K"is in the window on the data plate side
and the red distributor tooth appears in each distributor inspection window.
Page 74-07
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 74-6. Painted Tooth Centered
in Timing Window
Figure 74-7. Timing Mark on Rotor
Aligned with Pointer
8. Install the magneto to engine gasket on the magneto flange.
9. Feel the magnet into its No. I neutral position as described in Step 7. With the engine in its
recommended No. I cylinder firing position of 20' BTDC. place the magneto in position on the engine
mounting pad and secure with the flange clamps finger tight.
10. Install short adapter leads made from Bendix terminal kit ( p a n number 10-382698) into magneto
switch terminals and connect to Bendix timing light (part number 11-91 10) or equivalent.
I I . Bump the magneto in the direction opposite the normal shaft rotation until the first breaker opens.
Due to normal tolerances. one breaker may open slightly before the other and timing should be done to the
first or early breaker. EL-enlytighten the magneto mounting clamps.
12. When the final timing check is done. back the engine up approximately 10 degrees: then carefull!.
bump the engine forward and observe the position that the breakers open. The first breaker should open at the
So. I engine firing position and the late breaker must open within 3 engine degrees from the first breaker
opening. I t makes no difference which breaker opens first.
13. Repeat Step I I if necessary until conditions of Step 12 are met. If the late breaker opens more than 3
degrees from the early one. the internal timing of the magneto must be rechecked. (Refer to Internal Timing.)
14. Torque the magneto securing clamps to 150 inch-pounds. Recheck timing once more and if
satisfactory disconnect the timing light and remove the adapter leads.
15. Reinstall the plugs in the timing inspection holesand torque to 12- I5 inch-pounds. Loosely install the
harness with clamps and o r brackets.
74- 10.03
Page 74-08
issued: Januarv 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
MAGNETO TIMING PROCEDURE. (Internal Timing)
I . Remove magneto cover.
2. Loosen flange clamps and remove magneto from engine.
3. Check condition of points: replace if necessary.
4. Rotate the magneto drive shaft until a main cam lobe touches the follower of the left main breaker
assembly and adjust the breaker points to an initial opening of .016 inch. Wire feeler gauge is recommended.
5. Adjust right main breaker contact assembly to an initial point opening of .O16 inch just as in Step 4.
6. Fixed contact support may be bent to adjust clearance. If suppon is bent. main breaker contact must
be rechecked. Torque breaker securing screws t o 20-25 inch-pounds.
-NOTE Bend bracket carefully. D o not correct by bending back if bent too
much; this weakens the bracket.
7. Position rotor so keyway is at I2 o'clock position and red painted distributor teeth are visible in
timing windows.
8. Loosen drive shaft nut and position the Rotor Holding Tool (Bendix p a n number 11-8465) under
washer or bushing on drive end of rotor shaft with clamp at 4 o'clock position so any shaft deflection caused by
clamping action will be in a plane parallel to breaker contacts. Tighten nut to secure holding tool to shaft.
Check to insure proper location of keyway and tighten adjustingscrew of holding tool to lock rotor in position.
9. Loosen rotor holding tool and turn magnet in direction of rotation until adjacent "R"("E"gap) mark
is aligned with pointer and lock in position. Both red painted teeth should beapproximately centered in timing
windows.
- NOTE The use of the timing light unit, part number 11-9110-1 available
from Bendir will simplijy the internal timing procedure and breaker
synchronization.
10. Connect the timing light black lead to any unpainted surface of the magneto.
I I. Connect the red timing light lead to the left breaker terminal and the green lead to the right main
breaker terminal. (Refer to Figure 74-8.)
12. Loosen rotor holding tool and move the rotor back a few degrees: then move it forward. Both lights
should go out to indicate opening of the main breakers when the timing pointer is indicating within the width
of the "R" mark and the red painted teeth are centered in timing windows.
13. If breaker timing is not correct. loosen cam securing screw (refer to Figure 74-9)and unseat main
breaker cam from taper. Using 11-3031 Retaining Ring Pliers inserted in holes in cam. rotate main breaker
cam in direction of rotation until left main breaker points just open and press cam onto taper. Tighten screw to
seat main breaker cam.
14. ,Loosen rotor holding tool to turn rotating magnet back a few degrees: then turn rotating magnet in
normal direction of rotation. Timing light should go out when timing pointer is aligned with "R" ("E" gap)
mark. Lock rotating magnet in position where points just open.
Page 7 4 0 9
Issued: January 2. 1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
1
1
Figure 74-8. Timjng Light Connected t o Magneto and Breakers
15. Loosen right main breaker securing screws and position breaker so cam follower is pressed against
cam with points closed. Tighten contact assembly securing screws to prevent contact assembly from bouncing
back when mo\.ed. Using a small mallet and drift. tap right breaker in until points just open.
16. Turn rotating magnet back a few degrees: then turn rotating'magnet in normal direction of rotation.
B o ~ htiming lights should go out within one degree o r half the width of "R" mark on rotor. If breakers are not
properly synchronized. reset right breaker.
17. Check right main breaker contact for 0.016 2 . 0 0 4 inch point opening and torque right breaker
contact securing screws t o 20-25 inch-pounds. If point opening is out of limits. repeat timing procedure settlng
left main breaker opening a t .O 16 _+ .002 inch. If right contacts open beyond .020 inch. set left contacts closer t o
.018 inch. If right contacts open less than .O I2 inch. set left contacts closer t o .0 14 inch.
18. Using timer light. recheck timing t o insure main breaker open within one-half the width ofwR"mark
and that retard breaker opens at correct degree setting. Using a wire feeler gauge. check left main breaker for
.016_+.002 inch point opening and right main breaker and retard breaker for .0162.004 inch point opening.
l j correct breaker timing cannot be achieved, remove magneto and
have it overhauled.
74- 1 &04
Page 74-10
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
280
DATA PLATE
(TOP OF MAGNETO)
LEFT MA
HIGH TENSION OUTLETS
RIGHT MAlN BREAKER
CONTACT ASSEMBLY
CfflTACT MSEMBLY
HIGH TENSION OUTLETS
------------------_--------
zm
1. RlQHT M A l N CONTACT A U E M I L Y
2. LEFT M A l N CONTACT ASSEMBLY
3 . SCREW
4 . LOCK WASHER
5 . F U T WASHER
6 . MAINCAM
VIEW A-A
a
3
i
I
Figure 74-9. Cam End View of Magneto
Page 74-1 1
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
19. Check capacitors for looseness in the magneto cover of the harness assembly and for any ph\.sical
damage. The capacitors should be checked for capacitance. series resistance and leakage. Capacitance should
be 0.34 t o 0.4 1 microfarads. The use of a Bendix condenser tester. p a n number I 1-1 767- I. -2 or -3or equi\ alent
will simplifl. this test. Replace defecthe capacitors and torque securing nut t o 60-70 inch-pounds.
-- NOTE
-
Spring in capacaor outlet may cause an indication of a short to
ground if adapter lead is not used. fRefer to Figure 74-4.)
I!tiPULSE COUPLISC.
I
a
REhlOVAL O F IMPULSE COUPLING.
I . l'sing hea\.y gloves o r shop cloth. grasp the coupling body firmly t o prevent the internal spring from
unu inding suddenly. Pull outward on the coupling body only enough t o release it from the cam assemhl!
Keep the coupling body close against the cam and allow the body t o turn as the spring unwinds. .4f;cr one o r
t u o turns. the spring coils uill wedge against the projections o n the body. restraining the bpring from fur1 her
unwinding.
2 . Look into the hole in body and note the location of the inner eye of spring where it engages \iith
mating recess in cam hub. Insert a screwdriver under spring end and pry spring eye out of recess. R e m o \ r the
bod! and spring together. Llncoil spring from body and pry spring eye from body recess to disengage spring
3 . Thread pr0tecth.e cap of I 1-702- 1 puller securely on end of shaft. Engage puller o \ e r protect i \ e cap
and cam assembl! with wide jaws of puller hooked under cam assembly a s shown in Figure 74-10.
1. ' ~ i g h t e npuller handle t o remove coupling from shaft. If coupling does not release with m a ~ i m u m
hand torque at puller handle. apply penetrating thread release compound between coupling and shaft. Then
while puller is still full! tightened. hold tip of hot heavy duty soldering iron in contact with hub of coupling cam
a\semhl!. Solder wetting of the tip at point of contact with the cam h u b will assist in heat transfer to the part>.
Retighten puller after about a minute of heat application.
Do not strike the puller with a hammer. If puller is struck with a
hammer the main bearings must be replaced.
5 . Do not tighten puller handle further after coupling cam releases from the shaft. This could damage
rhe fl! ueight if the flyw,eight is caught under the woodruff key. Remove the puller from the shaft. Then u hilr
holding hoth fl!.ueight tips inward. lift cam from the shaft. and remove woodruff key from rotor shaft.
ISSPECTIOS O F IMPCLSE COUPLING.
Check clearance beween each fl!.weight and each stop pin by the following met hod:
4. Bend the end of a stiff piece of wirc into a right angle. 1 8 inch long maximum.
B. Hold the magneto as shown in Figure 74- 1 I. Pull the heel of the flyweight outward \ \ i t h the
fabricated hooked wire and make certain that a feeler gauge of 0.015 of a n inch minimum thickne3s w i l l pas\
hcru.een the stop pin and the highest point of the fl\.ueight.
I.
74-10-07
Page 74-1 2
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure
7-1- I0
Remo\ ing Impulse Coupling
Figure 74-1 1 . Checking Fl!ueight to
Stop Pin Clearance
Figure 74-17. Stop Pin Installation Dimension
74-10-07
Paee 74-13
Revised: ~ u ~ u s t 1984
9.
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENAYCE MANUAL
NO. 35 DRILL
i
i
moa
800
FLYWEIGHT GAUGE
1l.lOlY1
.
Fipure
- 74- 1.1. Checking Flyweight Axial
W'ear with rill s h a n k
Figure 74-14. Checking FI!.ueight R a d ~ a l
Wear with Gauge
A true and accurate check o j the clearance between the flyweights
and stop pins can on!v be obtained by pulling theflyweight outward
as described D o not attempt the check by pushing in on the
jlyweight at point '2" of Figure 74-11.
2 . Inspect impulse coupling stop pins for damage. If pins are bent. damaged or excessi\.el!. w orn. remm e
pins using a suitable drift and arbor press. Press new pins into flange until dimension shown in Figure 74- 12 i5
obtained.
3. Visually inspect flyweight securing washers and flyweights. particularly in area around the asle hole
for crach.. Grip washers with pliers and exen moderate turning force to check looseness. I f washer mo\e, or
an! cracks are found. reject cam assembly.
1. Inspect for axial wear between fly*eight and axle using shank of a new No. 35 drill as a gauge. Hold
fl!ueight 4 0 the outer radius is in alignment with the rim of the cam flange and try t o insert the drill shank
hctueen the flange and flyweight as shown in Figure 74-14. D o not force the drill. I f the drill can be inserted.
replace the cam assembl!..
74-10-07
Page 74-14
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANVAL
Figure 74-15. Point3 of Coupling Bod! Wear
103
ACCEPTABLE
REJECT
Figure 74- 16. Acceptable and Deformed Coupling Spring4
Re! iced: ~ u ~ u 9.s 1984
t
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
5. lnspect for excess radial wear between the flyweight and axle using the 11-10041 flvweight gauge.
Insert the gauge betueen flyweights and against cam hub as shown in Figure 74-14. If the gauge cannot be
inserted easil! . remo\ e burr from edges of hub keyway with a small file. Hold the gauge firml! against the hub.
at the same tlme squeezing the flyweights against thegauge. If the innerend of either flyweight heel touches the
gauge. replace the cam assembly. If parts are near limits. check clearance between flyweight and gauge with a
001 inch feeler. If flyweight heel is tight on feeler. replace the cam assembly.
-- CA UTION
-
Never attempt to repair any pari oj a rejected cam and flyweight
assembly.
6 lnspect ears of the coupling body for grooves worn by the tail of the flyweights and w.ear at the
triggering ramp and cam stop contact areas. (Refer t o Figure 74-1 5.) If either ear shows a perceptible groo\ e or
a ridge can be felt when fingernail is drawn across the surface. replace the coupling bod!..
7. Inspect d r i ~ lugs
e of body. If wear is noted. measure difference between worn and unuorn areas on
dri\ e lug surface. If difference is in excess of ,015 of a n inch. replace the body.
8. N'ith spring released and free. it should form a smooth spiral curve with no sharp bends or tlat >pots.
(Refer t o Figure 74-16.) I f spring is deformed. replace it.
9. Inspect spring for cracks particularly at the ends and around spring eyes. Inspect coils of spring for
encessi\e s e a r . If grooves or ridges and worn in coils o r cracks are found. replace spring.
10. lnspect the housing for cracks. stripped threads o r other damage. Replace if necesar!.
I I N S T A L L A T I O S O F 1MPI:LSE COUPLING.
I . Check mating cam assembly and body for magnetization which would pre\.ent fl!,ueights from
engaging. Hold the assembly a s shown in Figure 74- 17 and push upper flyweight against body. When released.
fl!.ueight must drop dou.n, If flyweight sticks to body. parts are magnetized and coupling ma!. not function.
Perform test on both fl!.ueights.
2 . To demagneti7e. place body over shaft of a charged rotating magnet and spin bod!, rapidl! h! hand.
N'hile bod! is still spinning. invert magnet s o body falls off. Catch body in hand and repeat test for
magneti7ation.
1. Clamp one d r k e lug of the body in a padded jaw vise with the spring recess side up.
4. Orient the spring with the body for correct rotation. O n clockwisecouplings. the spring must coil in a
clocku.ise direction from the outside toward the center when viewed from the spring recess side of the bod!.
r Refer to Figure 74-18.) lnsen eye of outer end of spring into hole drilled in inner rim of bod!.
5 . 1'sing hea\.!. glo\.es to protect the hands. wind spring into body manually. lifting spring coils one at a
time o\.er projections on body. Extreme care should be used t o avoid scratching or nicking the spring. After
uinding the spring. brush a coating of light oil over the spring coils.
6 Pr!. u p one and one-half turns at the inner end of the spring with a small screwdriver and support in
position 3s shown in Figure 74-19.
7 . Engage recess in the hub on the cam assembly with eye at inner end of spring. With eye engaged.
rotate cam assembly slightly in direction t o unwind spring t o permit hub of cam t o slip into the inner turn of the
.prince. Rotate the cam in the opposite direction. windingspringslightly. until projections o n edge of cam clear
o \ r r the proiections on the body. Push the cam assembly down into the body. at the same time taking the
~ c r e ~ d r i \ out.
er
74- 10-08
Page 75-1 6
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
F ~ g u r c71-17. C h e c h ~ n gImpulw Coupling
for Mrlgnet17atinn
Figure 74-1 8. Orientation of S p r ~ n g
in Coupling Bod!
Figure 74-19. Lifting Inner End of Spring
74-10-08
Pane 74-17
Revised: .4ugust-9. 1984
PIPER AIRCRAFT
PA-32-311 1301T
MAINTENANCE MANUAL
8. Insert a spare rotating magnet. with woodruff key in taper. into cam assembly. Turn magnet slightl!.
in direction of coupling rotation ( t o wind spring). Lift magnet with cam only enough to clear projections on the
bod!. N'ind spring one-half turn and re-engage the cam assembly into the body.
9. Tension of the spring assembly in the assembled coupling when wound to point of impulse tripping
must not be less than 9 or more than 15 inch-pounds.
I
HARSESS.
IYSPECTION O F HARNESS.
I . Inspect co\er for cracks o r other damage. lnspect lead assemblies for abrasions. mutilated braid or
other ph!,rical damage.
2 . lnspect grommets for tears and eyelets for spark erosion.
3. Disconnect harness coupling nuts from the spark plugs and extract the lead terminations. lnspect
contact springs and compression springs for any damage o r distortion. Inspect slee\es for cracks or carbon
tracking.
4. lnspect coupling nuts and elbow assemblies for damaged threads or other defects.
Replace any damaged components per instructions given in
paragraph titled Maintenance of Harness.
5 . Tc5t continuit\. of each harness lead usinga High Tension Lead Tester. Part 50. I 1-8888 or I 1-8888- I
from Bendix as follous:
A . Connect black test lead to contact spring and red lead to eyelet of the same lead. ( Refer t o Figure
74-20
)
B. ObserLe that the continuity lamp illuminates.
Test insulation resistance of each harness lead by using the 1 1-8888 o r 1 1-8888- 1 tester as follou s :
.A. Attach the red high voltage test lead to contact spring of harness lead. (Refer to Figure 74-2 1 . )
B. Attach the black test lead to the ferrule of the same harness lead. (Refer t o Figure i 4 - 2 1 . )
C. Depress PRESS-TO-TEST pushbutton switch.
D . O b s e n e that indicator lamp flashes and G A P fires simultaneously as long as the PRESS-TOTEST snitch is held depressed. Whenever indicator lamp flashes and G A P fails to fire. lead under te5r i \
d e f e c t i ~ eand must be replaced.
h.
I
M A I S T E N A N C E O F HARNESS.
M ~ n o rrepair6 of the harness assembly. such a s replacement of contact springs. s1eeL.e~.compre44lon
\prlngk. e!elet5. or grommets can be accomplished with the harness mounted on the engine. Lead assernbl1e4
m,i! al4o be replaced with harness mounted on the engine unless inaccessibility of installation o r number of
lead4 t o be replaced makes it unreasonable.
74-20-03
Page 74-18
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
F ~ g u r c7 4 - 2 0 . Checking Harness Lead
Continuit!
Figure 74-21. Checking H a r m \ \ Lead
Insulation Resistance
I
1u
CUT NOTCH TO F I T SNUG
ON NO. 58 DRILL WITH
JAWS CLOSED
.
Figure 74-22. Modified Pliers
Figure 14-23. R e m o i ing Spring
F r o m Lead A\\ernhl!
Revised: .Augusi9. 1984
PIPER AIRCRAFT
MAINTENANCE MANUAL
To replace grommets or eyelets. pull the conductor through the shielding sufficiently to make eyelet
accessible. Remove the eyelet being careful not to damage conductor wire. Replace grommet and eyelet using
the "AB" groove of Crimping Tool KO. 1 1-4152 or a pair of diagonal pliers modified asshown in Figure 74-22.
Work the wire back into the shielding so the grommet fits properly against the ferrules in the plate. Slack in
shielding or wire can be removed by grasping the lead in one hand and sliding the other hand firmly along the
lead towards the magneto cover.
T o replace contact springs. insulating sleeves, compression spring or elbows, proceed as follows:
I . Using a Bendix 1 1-7073 needle or a mechanical pencil with the lead retracted. hook the end of the
contact spring as shown in Figure 74-23.
2. Using the needle or pencil, unscrew the spring.
3. Slide insulating sleeve and spring retainer assembly off end of lead assembly.
4. Replace defective component and reassemble as follows:
A. Fabricate a tool as shown in Figure 74-24 for installing the insulating sleeves over cable
terminals.
B. Slide elbow assembly over lead and attach nut finger tight to ferrule.
C. Push the fabricated tool through insulating sleeve and spring retainer assembly as shown in
Figure 74-25. Screw the cable terminal into the tool.
D. Work insulating sleeve and spring retainer assembly into position over the cable and unscrew the
tool. Install contact spring on cable terminal.
It may be necessary to lubricate the cable and insulating sleeve with a
thin film of DC-200 (200,000 centidokes) or commercial grade
alcohol to facilitate assembCy.
5. To replace one of the lead assemblies. proceed as follows:
A. Remove clamps and brackets from defective lead assembly. Cut cable ties from assembly and
discard.
B. Cut the eyelet from the lead and remove grommet.
C. Grip the ferrule of the lead with a pair of vise grip or water pump pliers and with a twist-pull
action remove the ferrule from the cover and discard ferrule. Pull lead from cover.
D. Thread pre-stripped end of replacement lead through cover.
-NOTE -
Replacement &ads are avaUablefrom Ben& in lengths of 1 7 thru 74
inches in 3 inch increments. Useneatest next longer length to replace
defective lcod
E. Scrape blue coating being careful not to cut braid for .SO of an inch from end of lead.
I
-- CA UTION
-
New ferrules must be used and inserted under the braid exactly as
stated in Step F.
F. Push back braid and thread a new ferrule over wire and under braid until braid just covers
knurling. (Refer to Figure 74-26.)
74-20-03
Page 74-20
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
2 - f IN.
k=
I
?
/.
DRILL NO. 47
IN. DEEP
BLEND O.D. TO I.D.
POLISH O.D.
12.000 IN.
I
MAT: NO. 30 D R I L L ROD OR EWIVALENT
Figure 74-24. Assembly Tool
Figure 74-25. Using Assembly Tool
Page 74-21
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
l l Y ' COATING SCRAPED
FROM BRElD
BRAID TO EDGE
OF KNURLING
BLUE COATING
Figure 74-26. Ferrule Positioned Under Braid
MATERIAL
- BRASS
Figure 74-27. Ferrule Seating Tool
74-20-03
Page 74-22
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
c m
-
11-3689
HANDLE
N W
DISTRIBUTOR
DlSTRlBUTOR
BLOCK
l?
Figure 74-28. Position of 11-8627 Kit and
Contact Spring at Stan of lnstallation
l
'
Figure 74-29; Position of 11-8627 Kit and
Contact Spring after Installation
r
C467
COAT
Figure 74-30. Lubricating Sleeve
Figure 74-3 1. Lubricating Ferrule Shoulder
74-20-03
Page 74-23
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUP.L
G. Pull the lead back into the cover to wedge thebraid between the tapers of the cover and ferrule.
H . Pro\ide a back up support for the cover and scat the ferrule using the 1 1-7074 Ferrule Seating
Tool (refer to Figure 74-27) and a mallet. Ferrule must be driven straight into the cover and full! seated.
I . Thread the pre-stripped end of conductor through grommet. Place a new eyelet on conductor
and crimp per instructions given in second paragraph of Maintenance of Harness.
6. When lead being replaced is of the elbow type. salvage the used e:bow and compression springs for
installation on replacement lead. Install theseand newsleeve andcontact spring(refer to Figures 74-28 and
74-29) furnished with replacement lead per instructions given in Steps I thru 4.
7. Reposition clamps and brackets and replace cable ties removed earlier. Clean the grommets. sleeves
and the inside of the cover with methylethylketone or denatured alcohol.
8. Spray grommets and sleeves with Fluorocarbon Spray. such as MS-S-122. supplied b!. Miller
Stephenson Chemical Co. Inc.. 16 Sugar Hollow Road. Danbury. Connecticut 06810. or equi\alent.
9. Prior to seating spark plug lead terminal in plug barrel use fluorocarbon spray on spark plug terminal
insulating sleeve (refer to Figure 74-30) to prevent heat from sticking sleeve to spark plug barrel. Lightly
lubricate the shoulder of ferrule to minimize twisting of ferrule. (Refer to Figure 74-3 1 .) Use GO-JO 50 LOK
manufactured by Goger Inc.. Akron. Ohio 44309.
10. Check cam securing screw. Screw must be torqued to 1 6 2 0 inch-pounds.
I 1 . With all high tension terminal grommets seated against the ferrules in the cover. attach the bottom
capacitor lead to the right main breaker and then the top capacitor lead to the left main breaker. Position the
co\er on the magneto and secure. Torque cover screws to 30-35 inch-pounds.
12. Carefull! route the high tension spark plug leads away from any hot spots such as manifolds and
sharp edges which might cause heat damage or chafing. Check leads for proper location in clamp, so when
clamps are tightened the leads will not be crushed. Leads should be taut to prevent chafing due to \ibration.
but not so taut as t o produce undue strain or leads.
13. After all leads hat.e been properly routed and secured t o the engine. recheck all clamp securing screw
for tightness. Fasten coupling nuts to proper spark plugs and torque as specified in Chart 7402. Do not allow
ferrules to turn while torquing nuts.
'
C H A R T 7402. COUPLING TORQUES
1
Spark Plug
Coupling Threads
Torque
(1b.-in.)
5 8-24
3 4-20
90-95
110-120
SPARK PLIVGS.
REXIOI'AL OF S P A R K PLG'GS.
I. Loosen the coupling nut on the harness lead and remove the terminal insulator from the spark plug
barrel uell.
74-2b02
Page 74-24
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 73-32. Remoting Spark Plug Fro7en t o Bushing
H'hen withdrawing the ignition cable lead connectionfrom theplug,
care must be taken to pull the lead straight out and in line with the
center line of the plug barrel; otherwise a side load will be applied.
which frequently results in damage to the barrel insulator and
connector. If the lead cannot be removed easily in this manner, the
resisting contact between the neoprene collar and the barrel
insulator will be broken by a rotary twisting of the collar. Avoid
undue distortion of the collar and possible side loading of the barrel
insulator.
I
2 . Rcmo\e the spark plug from the engine. In the course of engine operation. carbon and othcr
cornbustinn product\ w i l l be deposited on the end of the spark plug and will penetrate the lower thread. to
Enme degree. A \ a re\ult. greater torque is frequently required for removing a plug than for it5 in5tallation.
Accordingl!. the torque limitations given d o not apply t o plug removal and sufficient torque must be u\ed to
unscrew the plug. The higher torque in removal is not as detrimental as in installation. since it cannot stretch
.
a shearing load on this section and may. if sufficirntl! \e\erc.
the threaded .;ection. I t doe,. h o w e ~ e r impose
produce a failure in this location.
Revised: ~ u ~ u9.s 1984
t
P I P E R AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-- NOTE
-
Torque indicating handle should not be usedfor spark plug removal
because of the greater torque requirement.
?
Place spark plugs in a tray that will identify their position in the engine as soon as the!. are remo\ed
-NOTE
-
Spark plugs should not be used if they have been dropped.
,
1. Remoial of sei7ed spark plugs in the cylinder may be accomplished by application of liquid carhon
dinuide b!. a conical metal funnel adapter with a hole i n t h e a p e x j u s t largeenough t o a c c o m m o d a t e t h s funnel
ol a CO2 botrle. (Refer t o Figure 74-32.) When a sei7ed spark plug cannot be remo\,ed b!. normal mean\. the
funnel adapter is placed o \ e r and around the spark plug. Place the funnel of the C 0 2 bottle inside thc funnel
adapter and release the carbon dioxide t o chill a n d contract the spark plug. Break the spark plug loo4e u ith a
wrench. A warm c!.linder head at the time thecarbon dioxide is applied will aid in the remo\al of a n euct.\\i\ cl!
sei7ed plug.
5 . D o not allou foreign ob.iects t o enter the spark plug hole.
!
I S S P E C T I O S A S D CLEANING OF S P A R K PLVCS.
I . \'i\uall!. inspect each spark plug for the following non-repairable defects:
A . SeLerel! damaged shell o r shield threads nicked up. stripped o r cross-threaded.
~1
~a
i
i
1
~
i
B. Badl! battered o r rounded shell hexagons.
C. Out-of-round o r damaged shielding barrel.
D. Chipped. cracked o r broken ceramic insulator portions.
E. Badl! eroded electrodes worn t o approximately 5 0 5 of original si7e.
2 . Clean the spark plug a s required. removing carbon and foreign deposits.
3. Test the spark plug both electricaly and for resistance.
4 . Set the electrode g a p a t 0.015 t o 0.018 inches.
lVST.L\LLATIOS OF SPARK PLt'GS.
Rcfore installing spark plugs. ascertain that the threads within the cylinder are clean and not damaged
1 . Appl! anri-sei7e compound sparing!!. o n the threads and install gasket and spark plugs. Tori.:ue3hO
ro 420 inch-pounds.
Make certain the deep socket is properly seated on the spark plug
hexagon as damage to the plug could resuh if the wrench is cocked to
one side when pressure is wplied.
I
i
2 . Ci~refull! insert the terminal insulator in [he spark plug and tighten the coupling nut
I
71-20-07
Page 74-26
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
SWITCHISC.
RE!iIO\'AL OF ICSITIOS SWITCH.
I . Insure the ignition switch is in the "OFF" position.
2. Gain access t o and dibconnect the power lead (+) from the battery.
Remo\e the ignition switch retaining nut from the switch on the forward side o f t he inhtrument panel
.
and nithdraw the \witch from the panel.
3 . Mark the wires and note their position o n the switch. then disconnect the wires.
INSTALLATION OF ICSlTlON SWITCH. (Refer to Figure 74-33,)
I . .Attach \tires to switch as shown in Figure 74-33.
2 . Check for proper operation of the ignition switch a s follou,s:
A. R e m o t e the P-lead from the right magneto.
B. 4ttach the P-lead of the right magneto t o a n ohmmeter and t o the airframe ground.
C . U'ith the switch in the "OFF". "L" or "START" positions. the ohmmeter should indicatc a
closed circuit
D. \\'ith the switch in the "R"or "BOTH" positions the ohmmeter should indicatc an open clrcult
3 Reconnect the P-lead to the magneto.
4. In\tall the ignition sw,itch in the instrument panel.
5 . Connect the power lead ( + I to the batter!.
1
I
Figure 74-11. Ignition Switch Wire Positions
74-30-03
Page 71-27
Revised: August-9. 1981
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEFT BLANK
CHAPTER
ENGINE INDICATING
PIPER AIRCRAFT
PA-32-301 ;301 T
MAINTENANCE MANUAL
-
-
CHAPTER 77 ENGINE INDICATING
TABLE OF CONTENTSIEFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
GRID
KO.
EFFECTIl'ITY
GENERAL
POWER
Manifold Pressure Gauge
Tachometer Indicator
Engine Oil Pressure Gauge
TEMPERATLIRE
Oil Temperature lndicator
Exhaust Gas Temperature Gauge (Alcor)
Remo\al of EGT Probe and Gauge
Cleaning and Inspection of EGT
Installation of EGT Probe and Gauge
Cylinder Head Temperature Gauge
77
- Cont./Effec.
Page - 1
Revised: August 11. 1983
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
GENERAL.
POWER.
MANIFOLD PRESSL'RE GACCE.
The manifold pressure gauge is a vapor proof. absolute pressure type instrument. Pressure from the
intake manifold of the engine is transmitted t o the instrument through a line. A pointer indicates the manifold
pressure available a t the engine in inches of mercury.
C H A R T 7701. TROUBLESHOOTING ( M A N I F O L D PRESSURE INDICATOR)
Cause
Trouble
Remedy
Excessive error at existing
barometric pressure.
Pointer shifted.
Replace instruments.
Excesswe error when engine is running.
Line Leaking.
Tighten line connections.
Sluggish or jerky pointer
movement.
Defective instrument.
Replace instrument.
Dull or discolored marking.
Age.
Replace instrument.
Incorrect reading.
Moisture or oil in line.
Disconnect lines and blou
out.
Page 77-01
Issued: January 2,1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
TACHOMETER INDICATOR.
The tachometer is connected to the engine accessory by a flexible cable and provides an indication of
crankshaft speed in revolutions per minute. The instrument has a recording mechanism for recording the time
that the engine is in actual operation.
CHART 7702. TROUBLESHOOTING (TACHOMETER)
--
Trouble
Cause
Remedy
Broken shaft.
Replace instrument.
Loose cable connections.
Tighten cable.
Rough spot on, or sharp
bend in shaft.
Repair or replace.
Excessive friction in
instrument.
Replace instrument.
Indicator changes in climb.
Excessive clearance in
speed cup.
Replace instrument.
Pointer goes all the way to
stop. more noticeable in
cold weather.
Excessive lubricant in instruments.
Replace instruments.
Pointer jumps at idle.
Speed cup hitting rotating
magnet.
Replace instrument.
Tachometer cable breaks.
Cable bent too sharply.
Reroute cable.
KO reading on indicator.
either permanent or intermittent.
Pointer oscillates excessively.
,
77-10-02
Page 77-02
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
ENGINE OIL PRESSURE GAUGE.
The oil pressure gauge is mounted in the cluster on the instrument panel. This gauge will indicate the
amount of oil pressure available at the pressurized engine oil passage.
CHART 7703. TROUBLESHOOTING (ENGINE OIL PRESSURE GAUGE)
Cause
Trouble
Remedy
Excessive error at zero.
Pointer loose on shaft.
Overpressure or seasoning
of bourdon tube.
Replace instrument.
Excessive scale error.
Improper calibration adjustment.
Replace instrument.
Excessive pointer oscillation.
Air in line or rough engine
relief.
Disconnect line and fill with
light oil. Check for leaks.
If trouble persists, clean
and adjust relief valve.
Sluggsh operation of
pointer or pressure fails
to build up.
Engine relief valve open.
Clean and check.
TEMPERATURE.
OIL TEMPERATURE INDICATOR.
The oil temperature indicator is mounted in the instrument cluster on the instrument panel. This
instrument will provide a temperature indication of the engine oil indegrees Fahrenheit. The instrument has a
temperature bulb located in the oil screen assembly, on the engine accessory section. .
.
CHART 7704. TROUBLESHOOTING (OIL TEMPERATURE INDICATORS)
Cause
Trouble
Remed y
Instrument fails to show
any reading.
Broken or damaged bulb.
Wiring open.
Check engine unit and
wiring to instrument.
Exassive scale error.
Improper calibration adjustment.
Repair or replace.
Pointer fails to move as
engine is warmed up.
Broken or damaged bulb
or open wiring.
Check engine unit and
wiring.
Dull or discolored marking.
Age.
Replace instrument.
Page 77-03
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
EXHAUST GAS TEMPERATURE GAUGE (ALCOR).
This instrument. which is commonly referred to as EGT. is used to aid the pilot in selecting the economical
fuel-air mixture for cruising flight as power setting a t 75% or less. It is a sensing device to monitor the fuel-air
mixture leaving the engine cylinders. This gauge is adjustable. If it is found defective after checking with
troubleshooting chart. it should be replaced. If the leads to the gauge arc defective in any way. they should be
replaced. When replacing leads. it is very important to use the same type and length of wire as the resistance of
the leads is critical for the proper operation of this gauge.
On PA-32-30lT models the EGT probe is mounted in the exhaust transition area.
REMOVAL OF EGT PROBE A N D GAUGE.
I. Disconnect wires from the EGT gauge a t the instrument panel.
2. Remove four bolts which secure the gauge to the instrument panel and remove the gauge.
3. Remove wires from the wire harness going to the engine.
4. Loosen the nut or clamp which secures the EGT probe to the exhaust system and remove the probe.
CLEANING AND INSPECTION OF EGT.
-
I
Unless mechanical damage is evident. broken glass. bent or broken pointer. or broken case. the following
checks should be performed before removing the instrument.
I . Remove probe and check for broken weld (at the tip end) or burnt off end. Measured resistance of
probe should be .8 ohms. Clean the connections with steel wool before reassembly.
2: Disconnect lead wires at instrument and measure. Resistance with lead wires connected to probe
should be 3.3 ohms. Clean connections with steel wool before reassembly.
3. With leads connected to instrument. heat probe with propane torch to dull red. The meter should read
up to the fourth graduation or approximately 1500°F. Before making this check. make sure that the
adjustment screw. which is located in the rear of the instrument case. is in the center of its travel. If this screu
has been turned to either end of full travel. it will shut instrument off and no indication will be shown on the
polnter. If meter still does not read, replace it.
77-20-04
Page 77-04
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-- CAUTION
-
D o not connect ohmmeter. N will bum out the movement of the
meter.
INSTALLATION OF ECT PROBE A N D GAUGE.
1.
2.
3.
4.
Install the probe and secure with locknut or clamp.
Route the thermocouple wires along with the existing wire harness to the instrument panel.
Install the EGT gauge into the instrument panel and secure with four bolts.
Connect the thermocouple wires t o the rear of the EGT gauge.
CHART 7705. EXHAUST GAS TEMPERATURE GAUGE (ALCOR)
I
Trouble
Gauge inoperative.
Fluctuat~ngreading.
Cause
Remedy
Defective gauge, probe
or wiring.
Check probe and lead
wires for chafing.
breaks or shorting
between wires and or
metal structure.
Adjusting potentiometer turned off scale.
Recalibrate instruments
Loose. frayed or broken
electrical leads or
faulty connections.
Clean and tighten
connections. Repair
or replace defectike
leads.
A
-
P age 77-05
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CYLINDER H E A D TEMPERATURE GAUGE.
The cylinder head temperature gauge is in the instrument cluster. located on the instrument panel. This
instrument measures the cylinder head temperature using a sender located in a cylinder head. The head
location is determined by the engine manufacturer. It is a n electrical instrument and is wired thru the
instruments circuit breaker.
C H A R T 7706. CYLINDER H E A D T E M P E R A T U R E GAUGE
Trouble
Cause
Instrument shows no
indication.
-
Instrument goes all
the way t o upper stop.
Remedy
Power supply wire
broken.
Repair wire.
Defective instrument.
Replace instrument.
Master switch off.
Wire broken between
sender and gauge.
Repair wire.
Defective sender.
Replace sender.
- END -
77-20-06
P age 77-06
Revised: September 23, 1981
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
CHAPTER
EXHAUST
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
-
--
-
CHAPTER 78 EXHAUST
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOK
SL!BJECT
78-00-00
78-0 1-00
GRID
SUBJECT
KO.
EFFECTI\'ITl'
GEKERAL
Inspection of Exhaust System
-
78 Cont./Effec.
Page 1
Revised: August 1 1. 1983
-
PIPER AIRCRAFT
PA-32=301/301T
MAINTENANCE MANUAL
GENERAL.
INSPECTION OF EXHAUST SYSTEM. (Refer to Figure 78-1 for PA-32-301 installations.)
A very thorough inspection of the entire exhaust system, including heat exchange shroud. (muffler and
muffler baffles on PA-32-301 or complete tailpipe assembly on PA-32-301T), stacks and all exhaust
connections must be accomplished at each 100 hour inspection. The possibility of exhaust system failure
increases with use. It is recommended that the system be checked even more carefully as the number of hours
increase; for example an inspection at the 700 hour period would be more critical than one in the 100 hour
period. The system should also be checked carefully before winter operation when the cabin heat will be in use.
-
NOTE
-
It is recommended that aR a b p h e s be @ted with a new (muffler
PA-32-301 or ta@ipe assembCy /or PA-32-MI T) at or near 1000
hours of service lifc.
On PA-32-301 removal of the tailpipe and stacksare required for inspection of the muffler baffles. On
PA-32-301T removal of the tailpipe is required for inspection of the cabin heat shroud and heat sink material
under the shroud on the tailpipe. Remove or loosen all exhaust shields, cabin heat shroud. heat blankets. etc..
as required to permit inspection of the complete system. Perform the necessary cleaning operations and inspect
all external surfaces for dents, cracks and missing pans. Pay panicular attention to welds. clamps. supports
and support attachment lugs. slip joints. stack flanges and gaskets. Inspect internal baffles or diffusers on
PA-32-301. Any cracks, warpage or severe oxidation are cause for replacement of muffler or tailpipe assembly.
If any component is inaccessible for a thorough visual inspection, accomplish one of the following:
1. Accomplish a submerged pressure check of the PA-32-301 muffler and exhaust stack at 2 psi air
pressure or perform a submerged pressure check of the tailpipe assembly at 20 psi air pressure on PA-32-30 IT
airplanes.
2. Conduct a ground test using a carbon monoxide indicator by heading the airplane into the wind.
warming the engine on the ground. advancing the throttle to full static RPM with cabin heat valves open. and
taking readings of the heated airstream inside the cabin at each outlet. Appropriate sampling procedures
applicable to the particular indicator must be followed. If carbon monoxide concentration exceeds .005
percent or if a dangerous reading is obtained on an indicator not calibrated in percentages, the muffler on the
PA-32-301 or tailpipe assembly on PA-32-301T must be replaced.
3. On PA-32-301 insure the proper installation of the shroud on the muffler upon reassembly.
A. Check the left end of muffler and shroud assembly to determine if the shroud retaining tabs aie
totally visible on the outside of the shroud. (Refer to Figure 78-1.)
B. If tabs are not visible and the shroud is mislocated, remove and reinstall the shroud in the proper
position.
C. Mislocation of the shroud could result in shifting of the shroud with a resulting reduction of
cabin heat and possible inability of the nose landing gear to fully extend to its down lock position.
Page 78-01
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
O W E A HOLISING
INNER BAFFLE
W- ALL WELDS AS INDICATED BY ARROW
INSURE TABS ARE OUTS1DE
OF SHROUD HOUSING
VIEW A
Figure 78- 1. Exhaust System Inspection Points
78-0 1-00
Page 78-02
Issued: January 2, 1980
PIPER AIRCRAFT
PA-32301 /301T
MAINTENANCE MANUAL
THlS PAGE 1NTENTIONALLY LEFT BLANK
CHAPTER
OIL SYSTEM
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
-
CHAPTER 79 OIL SYSTEM
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SL'BJECT
GRID
SUBJECT
KO.
EFFECTIi'ITY
DISTRIBUTIOS
Oil Cooler
Installation of Oil Cooler (PA-32-301)
Installation of Oil Cooler (PA-32-301T)
ISDICATIIVG
Oil Pressure Sensor
Removal of Oil Pressure Sensor
Installation of Oil Pressure Sensor
-
79 Cont./Effec.
Page 1
Revised: August 11. 1983
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
DISTRIBUTION.
OIL COOLER.
INSTALLATION OF OIL COOLER. (PA-32-301 .)
(
I . When installing fittings in the oil coolers, care should be used to prevent excessice torque b e ~ n g
applied to the cooler. When a rectangular fitting boss is provided. backup wrench should be used. employ~nga
scissor motion. so that no load is transmitted t o the cooler. When the oil cooler has a round fitting boss. care
should be taken not to permit excessive torque on the fittings.
2. If a pipe thread fitting is used. it should be installed only far enough to seal with sealing compound.
3. Apply Lubon No. 404 to all male pipe thread fittings; d o not allow sealant to enter the s>stern.
4. If fitting cannot be positioned correctly using a torque o f 9 t o I5 foot-pounds. another fitting should
be used.
5 . When attaching lines to the cooler. a backup wrench should be used.
6. After installat~on.inspect the cooler for distorted end cups.
7. Run-up engine. After run-up. check for oil leaks.
INSTALLATION OF OIL COOLER. (PA-32-301T.)
1
I . The fittings on this installation utilize O-ring gaskets. It is recommended that the O-rings be replaced
whenever a connection is opened.
2. When installing fittings in the oil cooler. care should be used to prevent excessive torque being applied
to the cooler. Allowable torque for H in fittings is 9 to 15 foot pounds. When a rectangular fitting boss is
provided. a backup wrench should be used employing a scissor motion so that no load is transmitted to the
cooler.
3. Use care when installing flexible hose assemblies. (Refer to Chapter 20. Installation of Flexible Hose
Assemblies.)
4. When tightening nuts on flexible hose assemblies with flared fittings. first tighten the nut finger-tight
and then tighten with a smooth jawed wrench to the torque specified in Chart 9101.
5 . After installation. inspect the cooler for distorted end cups.
6. Run-up engine. After run-up, check for oil leaks. During leak testingany one nut may be tightened a n
additional one-sixth turn maximum. if the fitting still leaks, the fluid line shall be removed and replaced.
Page 79-01
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MMNTENANCE MANUAL
INDICATING.
I OIL PRESSURE SENSOR.
The oil pressure sensor switch is incorporated in the oil line to the oil pressure gauge and is located on the
aft side of the bulkhead at fuselage station 49.50.
REMOVAL OF OIL PRESSURE SENSOR.
Access to the sensor unit gained by reaching up under the instrument panel. Removal is accomplished by
the following:
1. Disconnect the two electrical leads.
2. Unscrew the sensor unit from the bulkhead fitting.
3. Catch spillage and cover hole to prevent foreign matter from entering oil line.
INSTALLATION OF OIL PRESSURE SENSOR.
I . Seal sensor unit pipe threads with thread sealant tape (3M-Teflon KO.48 x 1 4").
2. Screw the sensor unit into the bulkhead fitting.
3.
4.
Reconnect the two electrical leads.
Perform operational check.
- END -
79-31-02
Page 79-02
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
THIS PACE INTENTIONALLY LEFT BLANK
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEFT BLANK
SARATOGA
MAINTENANCE MANUAL
CARD 3 OF 3
PA-32-3011301T SARATOGA
I
1
a
Courtesy of Bomar Flying Service
www.bomar.biz
PIPER AIRCRAFT CORPORATION
a
(PART NUMBER 761 721 1
3A 1
PIPER AIRCRAFT
PA-32-301ISOlT
MAINTENANCE MANUAL
INTRODUCTION.
This PIPER AIRCRAFT Maintenance Manual is prepared in accordance with the G A M A (General
Aviation Manufacturcn Association) fonnat. This maintenance manual isdivided into various Groups which
enable a broad separation of contents (Chapters) within each group.
The various Chapten are broken down into major systems such as Electrical Power. Flight Controls.
Fuel. Landing Gear. ctc. The SysemlChapten arc amnged mom or kss alphabetically rather than by
precedence or importance. All SystemIChaptersare assigned a number. which becomes the first element of a
standardized numbering system. Thus the element '32" of the number series 32-00.00 refers to the
System Chapter on "Landing Gear." All information pertaining to the landing gear will be covered in this
System Chapter.
The major System {Chapters are then broken down into Sub-system 'Sections. These sections are
identified by the second element of the standardized numbering system. The numberU40"of the basic number
series 32-40-00 is ,for the "Wheels and Brakes" portion of the landing gear.
The indisidual units within a Sub-System'Section may be identified by a third element of the
standardized numbering system. such as 3240-01. This number could be assigned by the manufacturer to fit
the coverage requirements of the publication.
Example:
CHAPTER/ SYSTE
LASDING GEAR
UB-SYSTEMS
WHEELS AND BRAKES
\-JNDIVIDUAL
UNITS
NOSE WHEEL REMOVAL
This manual does not contain hardware callouts for installation. Hardware callouts are only indicated
where a special application is required. To confirm the correct hardware used. refer to the PA-32-301 301T
Pans Catalog P.h' 761 720. and FAR 43 for proper utilization.
Introduction
Page 1
Added: May 21. 1980
-
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
AEROFICHE EXPLANATION AND REVISION STATUS
The Maintenance Manual information incorporated in this set of Aerofiche cards has been arranged in
accordance with the general specifications of Aerofiche adopted by the General Aircraft Manufacturer's
Association. (GAMA). The information compiled in this Aerofiche Maintenance Manual will be kept current
hy revisions distributed periodically. These revisions will supersede all previous revisions and will be complete
Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set.
Conversion of Aerofiche alpha numeric code numbers:
First number is the Aerofiche card number.
Letter is the horizontal line reference per card.
Second number is the vertical line reference per card.
Example: 2J 16 = Aerofichc card number two of given set. Grid location J 16.
T o aid in locating the various chapters and related service information desired. the following is pro\ ided:
A complete manual System,Chapter Index Guide is for all fiche in this set.
A complete list of illustrations is for all fiche in this set following System Chapter Index.
A complete list of Charts is for all fiche in this set following list of Illustrations.
A complete list of paragraph titles and appropriate Grid location numbers is git,en at the beginning of
each Chapter relating to the information within that Chapter.
5. Identification of Revised Material:
Revised text and illustrations are indicated by a black vcnical line along the left-hand margin of
the frame. opposite revised. added or deleted material. Revision lines indicate only current re\-isions
with changes and additions to or deletions of existing text and illustrations. Changes in
capitalization. spelling. punctuation. indexing. the physical lociltion ofthe material or complete page
additions are not identified by revision lines.
A reference and record of the material revised is included in each chapter's Table ot'
Contents Effectivit!. The codes used in the effectivity columns of each chapter are defined as follows:
I.
2.
3.
4.
TABLE O F CONTENTS EFFECTIVITY CODES
Original Issue:
None
First Revision:
Revision ldentification. ( I R ~ o n i h - y e a r )
Second Revision: Revision Identification. (2R Month-Year)
All subsequent revisions will follow with consecutive revision numbers
such as 3R. 4R. etc.. along with the appropriate month-year.
Added Subject: Revision Identification. (A Month-Year)
Deleted Subject: Revision Identification. (DMonth-Year)
Introduction
Page
-2
Revised: August 11.-1983
.
PIPER AIRCRAFT
PA*32-B1/3OlT
MAINTENANCE MANUAL
6. Revisions t o Maintenance Manual 761 721 issued January 2, 1980 arc a s
follows:
Effectivity
Publication Date
January 2, I980
May 21, 1980
August 19, IS0
September 23, 1981
Fcbwry 19,1982
August 23, 1982
August 11, 1983
August 9, 1984
A u p s t 15. 1985
April a,1986
July 30, 1986
September 20. 1986
May 12, 1987
Aerofichc Card Effectivity
1.2 and
1. 2 and
I, 2 and
I, 2 and
I, 2 and
1, 2 and
1, 2 and
1, 2 and
3
1
1
1
3
3
3
3
3
3
3
3
-
1
The date on Aerofiche cards must not be earlier than the date noted for the respective card effectivity. Consult
the latest Aerofiche card in this series for current Aerofiche ard effectivity.
This publication contains material revised as of August 15, 1985
(with four interim revisions effective April 30, 1986,July 30, 1986,
September 20, 1986 and March 16, 1987).
INTERIM CHANCE
Revisions appear in chapter 5 of a r d 1.'Ibere m no other cbnges
in this mrintenmnce mmurl. Pku,direrrd your current card 1and
replace it with this nviwd on.D O NOT DISCARD CARDS 2 or
3.
Introduction
Page 3
Interim Reddon: March 16, 1987
-
j
I
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
EYGIYE:
O\erhaul Manual =
-
AVCO LYCOMING OVERHAUL MASL'AL
DIRECT DRIVE ENGINE P S 60194-7
A\co Lycominp Division
W illiamspon. Pa. 17701
AVCO LYCOMJNG - P N PC-102
Ports Catalog =
Avco Lycoming Division
Williamsport. Pa. 17701
Operators Handbook = A\'CO LYCOMING 10-540 and TIO-540
SERIES AIRCRAFT ENGINES - P N 60197-10
Awe Lycoming Division
W illiamsport. Pa. 17701
PROPELI.ER:
O\.erhauI Instruct ions = H ARTZELL COMPACT COXSTANT SPEED
and FEATHERISG PROPELLER P S 1 17-D
Hart7ell Propeller I nc.
Piqua. Ohio 45356
M .A(;\ ETOS:
Installation. Operation
and Maintenance
D-2000 and D-2200 SERIES MAGNETO
In~truction5=
IGSlTlON SYSTEM P N L-928
Rendix Electrical Components Division
Sidney. New York 13838
-
-
-
AI'TO FLIGHT:
CEYTURY 41 AUTO PILOT
EDO-AIRE Mitchell
P.O. Box 610
Mineral Wells. Texas 76067
Introduction
Page 4
Revised: August 9. I984
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
PIPER PC'BLICATIONS.
COMM CSICATIOSS:
Remo\al. Installation
and Maintenance
761 502 AutKontrol Ill B Senice Manual
Instructions =
761 481 AuroFlite I1 Scnice Manual
753 77 1 Pitch Trim Senice Manual
Radio S e n ice and
Maintenance Manual = 761 713 Avionics Wiring Diagram Ser\ ice Manual
Vol. I and Vol. 11 ( 1979)
REPAIRS:
A.B.S Thermoplastic
Landing Gear Wheel
and Strut Fairing
Repair Instructions = 761 708V A.B.S. Thermoplastic Landing Gear
Wheel and Strut Fairing Repair Instruction Manual
P.4RTS CATALOG =
PA-32-301 30 IT
761 720
PERIODIC ISSPECTIOS
REPORT FORM =
230 1046
PA-32-30 l 30 1 T
PROGRAMMED IKSPEC-
Introduction
Page 5
Revised: August 9, 1984
-
PIPER AIRCRAFT
PA-32301/301T
MAINTENANCE MANUAL
GAMA SYSTEMICHAPTER INDEX GUIDE
SYST
CHAP
SU B-SY S T
SECTION
TITLE
AEROFlCHE
G R I D $0.
AIRWORTHINESS
T I M E LIMITS, M A l N T C H E C K S
DlMENSIOSS AND AREAS
LIFTISG AND SHORIXG
LEVELlh'G A N D W E I G H I S G
ICI
TOWlSG AND TAXIISG
PARKlSG A S D MOORlSG
REQUIRED PLACARDS
SER\'ICING
- LUBRICATIOX
STASDARD PRACT
- AIRFRAME
E N V I R O N M E N T A L SYSTEM
AUTOFLIGHT
COM MUSICATlOKS
ELECTRICAL P O W E R
EQUIPMEST: FURNISHINGS
FLIGHT CONTROLS
FUEL
LANDING G E A R
LIGHTS
NAVIGATION & PITOT! S T A T I C
OXYGEN
Introduction
Page 6
-
Revised: August 11,-1983
PIPER AIRCRAFT
PA-32-241/301 T
MAINTENANCE MANUAL
G A M A SYSTEMICHAPTER
SYST
CHAP
S l ' R-SYST
SECTIOS
INDEX GUIDE (cont)
AEROFICHE
GRID SO.
TITLE
\'ACL:CM
ELECTRICAL
STRUCTURES
DOORS
STABILIZERS
H'I S DON'S
H'ISGS
PROPELLERS
-
STANDARD PRACTICES ENGINES
.
POWER PLAXT
EXGISE FUEL SYSTEM
IG\ITIO\
EKGISE ISDICATISG
EXHAL'ST
OIL SYSTEM
STARTING
TURBINES
CHARTS AND WIRING DIAGRAMS
SPECIAL PURPOSE EQUIPMENT
Introduction
Page 7
Revised: August 9, 1984
-
PIPER AIRCRAFT
PA-32-30 1/30 1T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS
0.
SUBJECT
GRID SO.
Three Vieu of PA-32-301
Three View of PA-32-301T
Station Reference Lines (PA-32-301)
Station Reference Lines (PA-32-30 1T)
Access Plates and Panels
Jacking
Leveling Airplane
Weighing
Placards and Decals
Fuel Filter Bowl and Screen
Servicing Points
Main Gear Oleo Struts (Cut-Away View)
Lubrication Chart (Landing Gear. Main)
Lubrication Chart (Landing Gear. Nose)
Lubrication Chart (Control System)
Lubrication Chart (Air Conditioning Condenser)
Lubrication Chart (Cabin Door. Baggap Door
and Seat)
Lubrication Chart (Power Plant. Propeller and
Control Pi\.ot Points)
Lubrication Chart (Back-Up Extender and Fuel Selector)
Torque Wrench Formula
Method of Installing Rod End Bearings
Cherrylock Rivet Removal
Hose Line Markings
Flareless-Tu be Fittings
Maximum Distance Between Supports for Fluid Tubing
Cabin Heater. Defrosters and Fresh Air System
(PA-32-30 1 )
Cabin Heater. Defroster and Fresh Air System
(PA-32-30 IT)
Air Conditioning System lnstallation (Typical)
Service Valves
Test Gauge and Manifold Set
Manifold Set Operation
Leak Test Hookup
Evacuation Hookup
Charging Stand
Charging Hookup
Compressor and Fabricated Oil Dipstick
Compressor and Alternator Belt Installation
Magnetic Clutch
Condenser Air Scoop lnstallation
Expansion Valve
Components Installation
Air Conditioning Wiring Schematic (Early Models)
Air Conditioning Wiring Schematic (Later Models)
1e15
I E23
I F4
I F5
I F6
IF?
I F9
lFll
1f13
1f17
1f18
I F20
I F24
IG I
I C3
164
1g5
Introduction @
Page 8
Revised: August 11; 1983
-
PIPER AIRCRAFT
PA-32-3Q1/30 1T
MAINTENANCE MANUAL
LIST OF ILLLSTRATIONS (cont)
SUBJECT
FIGURE $0.
GRID SO.
Emergency Locator Transmitter Schematic
(Narco)
ELT Portable Folding Antenna (Sarco)
ELT Using Fixed Aircraft Antenna (Narco)
Avionics Master and Emergency Switch Circuit
Exploded View of Alternator Prestolite
Lamp-Bank Load
Removal of Slip Ring End Bearing
Removal of Rectifier
Remo\al of Drive End Head
Removal of End Head Bearing
Testing Rotor for Ground
Testing Rotor for Shorts
Installation of Bearing
Installation of Rectifier
Terminal Assembly Prestolite
Slip Ring End Bearing Assembly
Testing Alternator
Brush Installation
Internal Wiring Diagram
Alternator Exploded View Ford
Rear Vieu Terminal Identification
Stator Core and Windings
Rectifier Assembly
Internal Relationship of Alternator Components
Rectifier Ground and Positive Diode Test
Stator Ground and Negative Diode Test
Field Circuit Open or Ground Test
Alternator Housing Disassembly
Rear Housing Components
Front Housing Disassembly
Front Hou~ingComponents
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
-
-
-
Introduction
Page 9
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32.301 1301T
MAINTENANCE MANL'AL
LIST OF ILLUSTRATIONS (mnt)
FIGURE SO.
SUBJECT
GRID SO.
Diode Testing
Front Housing Assembly
Rear Housing Bearing and Brush Assembly
l nstallation
Rear Housing Components
Housing Assembly
Alternator Installation Ford
Seat Back Lock
Rod End lnstallation Method
Control Column Assembly
Aileron Controls
Aileron Rigging
Bellcrank Rigging Tool
Aileron Rigging Tool
Aileron Rudder Interconnect
Rudder Controls
Rudder Rigging Tool
Rudder Travel Adjustments
Rudder Rigging
Clamping Rudder Pedals
Rudder Trim Control
Rudder Steering Pedal Assembly
Stabilator Controls
Stabilator Rigging
Stabilator Travel Adjustments
Methods of Securing Trim Cables
Stabilator Trim Controls
Wrapping Trim Barrels
Stabilator Rigging Tool
Flap Cant rols
Flap Step Adjustment
Flap Rigging Tool
C1
Fuel System (PA-32-30 I )
Fuel System (PA-32-301T)
Fuel Cell Installation
l nstallation of Locking Fuel Cap
Fuel Filter
Fuel Gauge
Main Gear Oleo Strut Assembly
Main Gear lnstallation
Kose Gear Oleo Strut Assembly
-
Introduction
Pant 10
Revised: A U ~ U SI~i, I 983
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
FIGL'RE SO.
SUBJECT
GRID SO.
Sose Gear lnstallation
Clamping Rudder Pedals in Neutral Position
Rudder Pedals at Neutral Angle
Main Wheel Assembly
Nose Wheel Assembly
Brake Assembly
Removal and lnstallation of Anchor Bolts
Brake Disc Minimum Thickness
Brake System lnstallation
Brake Master Cylinder (Hand, Parking Brake)
Toe Brake lnstallation
Brake Cylinder ( 10-30) (Toe Brake)
Brake Cylinder (17000) (Toe Brake)
Landing Gear Fairing lnstallation
Strobe Light Connections
P~tot-StaticSystem lnstallation
Fixed Oxygen System lnstallation
Test Apparatus for Testing Oxygen System
Oxygen Tubing lnstallation
lnstallation of Swagelock Fittings
Oxygen Cylinder and Reeulator Assembly
Oxygen System Recharge Valve lnstallation
Oxygen Pressure Gauge lnstallation
Oxygen l nstallation (Portable)
Skin Material and Thickness
Surface Scratches. Abrasions or Ground-in-Dirt
Deep Scratches. Shallow Nicks and Small Holes
Mixing of Epoxy Patching Compound
Welding Repair Method
Repairing of Cracks
Various Repairs
Repair of Stress Lines
Repair of Impacted Damage
Snubber lnstallation
Empennage Group
Stabilator Balancing
Rudder Balancing
Windshield lnstallation (Typical)
Introduction
Page 11
Revised: August 11. 1983
-
PIPER AIRCRAFT
PA-32-301130 1T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
FIGURE SO.
SUBJECT
GRID KO.
Side Window Installation. Single Pane (Typical)
Wing lnstallation
Aileron and Flap lnstallation
Aileron Balance Configuration
Typical Nicks and Removal Method
Propeller lnstallation (PA-32-301)
Three Blade Propeller lnstallation (PA-32-30 1)
Propeller lnstallation (PA-32-3OIT)
Three Blade Propeller lnstallation (PA-32-30 IT)
Propeller Governor
Engine lnstallation (PA-32-30 1)
Engine Mount lnstallation (PA-32-301T) (Dynafocal)
Engine Mount lnstallation (PA-32-MIT) (Lord Mounts)
Fuel Injector
Schematic Diagram of RSA Fuel Injection System
Fuel-Air Bleed Nozzle
Adjustment of Engine Controls
Height of Spring in Distributor Block Tower
Contact Points
Engine Timing Marks
Timing Light Connected to Magneto
Tlming Marks on Magneto Rotor
Painted Tooth Centered in Timing Window
Timing Mark on Rotor Aligned with Pointer
Timing Light Connected to Magento and Breakers
Cam End View of Magneto
Removing Impulse Coupling
Checking Flyweight to Stop Pin Clearance
Stop Pin lnstallation Dimension
Checking Flyweight Axial Wear with Drill Shank
Checking Flyweight Radial Wear with Gauge
Points of Coupling Body Wear
Acceptable and Deformed Coupling Springs
Checking Impulse Coupling for Magnetization
Orientation of Spring in Coupling Body
Lifting Inner End of Spring
Checking Harness Lead Continuity
Checking Harness Lead insulation Resistance
Modified Pliers
Removing Spring From Lead Assembly
Assembly Tool
Using Assembly Tool
Ferrule Postioned Under Braid
Ferrule Seating Tool
Position of 11-8627 Kit and Contact Spring at
Start of lnstallation
Introduction
Page 12
Revised: August 11, 1983
-
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
FIGl'RE KO.
GRID S O .
SUBJECT
Position of 1 1-8627 Kit and Contact Spring
After Installation
Lubricating Sleeve
Lubricating Ferrule Shoulder
Remo\.ing Spark Plug Froten to Bushing
Ignition Switch Wire Positions
Exhaust S!.stem Inspection Points
Exploded View of Gear Reduction Starting Motor
Turning Starting Motor Commutator
Testing Motor Armature for Shorts
Testing Motor Fields for Grounds
So-Load Test Hook-Up
Stall-Torque Hook-Up
Turbocharger Installation
Tire Balancer Fixture
Orifice Replacement Tool
Fabricated Tool for Baggage Door Lock
Retainer Ring Tool
Fabricated Aileron Bellcrank Rigging Tool
Fabricated Rudder Rigging Tool
Fabricated Aileron and Flap Rigging Tool
Fabricated Stabilator Rigging Tool
Control Surface Balancing Tool
Rejer to Card 3, Grid No. 3011 /or Electrical Schematic Index.
Introduction
Page 13
Rwised: August 9. 1984
-
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
LIST OF CHARTS
CHART SO.
SUBJECT
GRID SO.
Leading Particulars and Principal Dimensions
Thread Lubricants
Type of Lubricants .
Hose Clamp Tightening (Initial Installation)
Blower System Wire Color Codes
Troubleshooting (Air Conditioner)
Troubleshooting (Air Conditioning System)
Temperature Pressure
Aluminum Tubing Torque
System Vacuum Chan
Compressor Oil Charge
Troubleshooting (Alternator)
Troubleshooting (Battery)
Alternator Specifications (Prestolite)
Alternator Belt Tension (Prestolite)
Hydrometer Reading and Battery Charge Percent
Electrical System Component Loads
Troubleshooting (Surface Controls)
Cable Tension Vs. Ambient Temperature
Troubleshooting Chart (Fuel System)
Fuel Cell Repair Equipment Lists
Sender Fuel Quantity Gauge Tolerances
Troubleshooting Chart (Landing Gear)
hose Gear Alignment Tolerances
Electrical System Troubleshooting
Troubleshooting (Rate of Climb Indicator)
Troubleshooting (Altimeter)
Troubleshooting (Airspeed T u k s and Indicator)
Troubleshooting (Gyro Horizon Indicator)
Troubleshooting (Directional Gyro Indicator) .
Troubleshooting (Magnetic Compass)
Troubleshooting (Turn and Bank Indicator)
Troubleshooting (Oxygen System)
Oxygen System Component Limits (Fixed)
Filling Pressures for Certain Ambient Temperatures
Oxygen System Component Limits (Portable)
Troubleshooting (Vacuum System)
List of Materials (Thermoplastic Repair)
Propeller Specifications (PA-32-301)
Propeller Specifications (PA-32-30 1T)
Engine Troubleshooting Chart
Troubles hooting (Magneto)
Coupling Torques
.
Introduction
Page 14
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
1-IST OF CHARTS (cont)
SL'BJ ECT
Trouhleshooting ( Manifold Pressure Indicator)
Troubleshoot ing (Tachometer)
Troubleshooting (Engine Oil Pressure Gauge)
Trouhleshooting (Oil Temperature Indicators)
Troubleshooting (Exhaust Gas Temperature
Gauge) ( Alcor)
Troubleshooting (Cylinder Head Temperature Gauge)
Troubleshooting (Staner)
Starting Motor Specifications
Troubleshoot in? (Turbocharger)
Tube and Hose Assembly Torque
Recommended Nut Torques
Decimal Conversions
Con\.ersion Charts
List of Consumable Materials
Electrical Wire Coding
Electrical S ~ m b o l s
GRID SO.
ZL7
ZLH
ZL9
ZL9
Introduction
Page I5
Revised: August 9. 1984
-
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
I
CHAPTER
STARTING
PIPER AIRCRAFT
PA-32-301 / B I T
MAINTENANCE MANUAL
-
CHAPTER 80 STARTING
TABLE OF CONTENTS/EFFECTlVITY
CHAPTER
SECTIOS
SL'BJECT
SUBJECT
GRlD
KO.
EFFECTIVITY
GESERAL
Description and Operation
Troubleshooting
CRASKING
Maintenance of Starting System
Starting Motor
O\erhaul of Staning Motor
Rerno\.al of Starting Motor
Disassembl) of Staning Motor
Brushes
Armature
Field Coils
Brush Holders
Gear and Pinion Housing
Bendis Dri1.e
Assernbl! of Starting Motor
Testing of Starting Motor
Bench Test
Starting Motor Control Circuit
Starting Motor Sen-ice Test Specifications
Starting Through External Power Receptacle with
Airplane's Batten Kearly Depleted
-
80 Cont./Efftc.
-
Page 1
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
GENERAL.
DESCRIPTION AND OPERATION. (Refer to Figure 80-1.)
t h e gear reduction staning motor consists of six major components: The Commutator End Head
Assembly, The Annature. The Frame and Field Assembly, Tbe Gear Housing, The Pinion Housing, and The
Bendix Drive Assembly. When the staning circuit is enagbd, batterycurrcnt isapplied to the staning motor
terminal. Current flows through the field coils, crating a strow mametic field. At the same time. current
flows through the b w h e s to the commutator, through the a r r ~ t u r windings
c
to ground. The magnetic force
created in the armature combined with that created in the field windings begins to turn the armature.
The gear cut on the drive end of the armrture s h f t extends through the gear housing. where it is
supponed by a roller karing. The gear mates with the teeth of the reduction gear that drives the Bendix shaft.
The shaft is keyed to the reduction p a r . The k n d i x drive is held in position on the shaft by a "spiralWpin.The
shaft is supponed in the gear housing by a closed end rolkr bearing and in the pinion housing by a graphitized
bronze karing.
When the armature turns the reduction gear, the Bendix drive pinion meshes with the flywheel ring gear
by inertia and action of the screw threads within the Btndixrkeve. Adetcnt pin m p g e s ina notch in the screw
threads which prevents demeshing if the engine fails to s u n when the starting circuit is detnergized.
When the engine reaches a predetermined speed, centrifugal action forces the detent pin out of the notch
in the screw shaft and allows the pinion to demesh from the flywheel.
TROUBLESHOOTING.
peculiar to the gear reduction starting motor arc listed in Chan 8 101 along with their probable
I causeTroubles
and suggested remedies.
PIPER AIRCRAFT
PA-32-30;/301T
MAINTENANCE MANUAL
CHART 8001. TROUBLESHOOTlNG (STARTER)
1
a
I
I
I
9
Trouble
Motor fails to operate.
Cause
Remedy
Low battery charge.
Check and recharge if
necessary.
Defective or improper
wiring or loose connections.
Refer to electrical wiring
diagram and check all
wiring.
Defective starter solenoid
or control switch.
Replace faulty unit.
Binding. worn, or improperly seated brush, or
brushes with excessive side
play.
Brushes should be a free f i t
in the brush boxes without
exmsive side play. Binding
brushes and brush boxes
should be wiped clean with
a cloth moistened w ~ t hundoped
psoline. A new brush
should be run in until at
least 50 percent seated:
however, if facilities are not
available for running in
brushes, then the brush
should be properly seated
by insening a strrp of number 000 sandpaper between
the brush and commutator. with the sanded side
next to the brush. Pull sandpaper in the direction of rotation. being careful t o keep
it in the same contour as the
commutator.
-- CA UTION
-
D o not use marse sandpqprr or emery doth. Afrer
lCOIkg, clean thwoughly to
remove all sand and metal
partick to prevent excessive w e . K u p motor
&wing frrr from sand or
meid portkles.
80-00-02
Page 80-02
Revised: August 23, 1982
PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
CHART 800 1. TROUBLESHOOTING (STARTER) (cont)
Trouble
Motor fails to operate.
(cont)
Cause
Remedy
Dirty commutator.
.
Low motor and cranking
speed.
Shoned. grounded. or
open annature.
Remove and replace with
a n armature known to be
in good condition.
Grounded or open field
circuit.
Test. repair if possible or
replace with a new pan.
Worn. r o u ~ h .or improperly lubricated motor or
starter gearing.
Disassemble. clean. inspect. and relubricate.
replacing ball bearings
if worn.
Same electrical causes as
listed under "Motor fails
to operate."
Same remedies listed for
these troubles.
Binding. worn. or improperly seated brush or
brushes with excessive
side play.
See information above dealing with this trouble.
Dirty commutator. rough.
pitted. or scored.
Clean as outlined above.
Rough or scored commutator.
Remove and turn commutator down on a lathe.
Armature assembly not
concentric.
Reface commutator.
c
Excessive arcing of motor
brushes.
Excessite wear and arcing
of motor brushes.
If commutator is rough or
dirty. smooth and polish
with number 0000 sandpaper. If too rough and
pitted. remove and turn
down. Blow out all panicles.
80-00-02
Pact 80-03
PIPER AIRCRAFT
PA-32-a1/301T
MAINTENANCE MANUAL
--
•
-
p
p
Figure 80-1. Exploded viewof Gear Reduction Starting Motor
-
CRANKING.
MAINT ENANCE OF STARTING SYSTEM.
The starting circuit should be inspected at regular intervals, the frequency of which should be determined
by the amount of service and the conditions under which the vehicle is operated. It is recommended that such
inspection be made at each 100 hours and include the following:
I. The battery should be checked with a hydrometer to k sure it is fully charged and filled to the proper
level with approved water. A load test should k made to determine battery condition. If din and corrosion
have accumulated on the battery, it should k cleaned with a solution of baking soda and water. Be sure none
of the solution enters the battery cells.
2. The starting circuit wiring should k inspected to k sure that aU connections are clean and tight and
that the insulation is sound. A voltage loss test should k made to locate any high-resistance connections that
would affect starting motor efficiency. This test is mrde with a low-reading voltmeter while cranking the
engine or at approximately 100 amperes, and the following limits should k used:
A. Voltage loss from insulated battery post to staning motor terminal 0.3-volt maximum.
B. Voltage loss from battery ground post to starter frame 0. I-volt maximum.
-- NOTE
-
-
-
Ij whage loss is grtdltr than the &ow h & s , dditional tests
rhould be made over each porl oj the circuit to bcete the high
nsirimce connections.
80-10-01
Pap 80-04
W
e
d
:
January 2,1980
PIPER AIRCRAFT
PA-32-301 /MlT
MAINTENANCE MANUAL
-
NOTE
-
The proprr instollotion o j o d k r k s t a m i d s on d k d n u m cables
pesenrs qpeciol dvjicuky in t h t ad kdMdU # r n d i s kruloted
by an oxide coating. This oridr s#tbrl
be broltrndown in the
crimping ptvcess and some nuthod aqpb)ud to pnvvnt its
njonnhg (usually o mm&n p r v a m t b e j d l medal).For this
reason P e r does NOT m e n d the nplir at npluemmr oj
loose, corroded or other mmati#.rtay &bas
01rddtrhss
terminals on alminum c r b k Whena uusatwutory -tion
is
discowred Piper mommtnds t h t the mmp&e W e u u m b l y be
replaced. Should this not k -tint
Yi
s
m lo wloce rhe
uhuninum cab& m e w with l m p p r ab& m y , using a
copper cobk two sixes analkr. E n u p k : A t - l m h i n r r m cable
replocd with AN-3 copper able.
3. No lubrication is required on the starting motor except a t the time of overhaul. Then lubricate the
entire shaft under Bendix Drive. fill grooves in armature shaft at drive end and pack gear box uith 1.3 to 2.0
ounces of Lithium Soap Base Grease #I925 Molytex 'Ow o r equivalent.
4. The starting motor should be operated for a few seconds with the ignition switch off to make sure that
the pinion engages properly and that it turns freely without binding or excessive noise. Then the englne should
be started t u o or three times to see that the pinion disengages properly when the engine is turned off.
I STARTING MOTOR.
OVERHAL'L OF STARTING MOTOR.
If during the above inspection any indication of starting motor difficulty is noted. the starting motor
should be removed from the engine for cleaning and repair.
REMOVAL OF STARTING MOTOR.
To remolt the starting motor from the engine. first disconnect the p o u n d Able from the batter! post to
pre\,ent short circuiting. Disconnect the lead from the starting motor terminal. then take out the mounting
bolts. The motor can then be lifted off and taken t o the bench for overhaul.
DISASSEMBLY OF STARTING MOTOR.
I . Remove the frame screws from the commutator end head and pull end head and armature from
frame. Lift the brushes and lock in elevated position with brush springs. UK a puller t o remove the end head
from the armature. Use special bearing puller to remove the ~ a k ball
d bearing from the armature shaft.
2. Remove the frame screws that secure the gear housing t o the frame. Remove bolts and nuts holding
the gear housing t o the pinion housing and separate the two units. Pull k n d i x shaft from pinion housing. Do
not lose the steel spacer that is located on the pinion end of the shaft. Remove reduction gear. woodruff he!
and steel spacer from shaft.
80-10-05
Page 80-05
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
i
Figure 80-2. Turning Starting
Motor Commutator
Figure 80-3. Testing Motor Armature
for Shorts
Figure 80-4. Testing Motor Fields for Grounds
80-10-05
Page 80-06
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
3. Turn the Bendix pinion until it locks in the extended position. Locate Spiral" pin and use a punch to
remove. Slide drive assembly off the shaft. Do not attempt todisassemble the driveand do not dip it in cleaning
solvent.
4. To remove the roller bearings from the gear housing. use an arbor press and the correct bearing arbor.
DO KOT HAMMER OUT. Each pan should be cleaned and inspected for excessive wear or damage.
Bearings should be checked for proper clearance and evidence of roughness or galling. Oil and din should be
removed from insulation and the condition of the insulation checked.
BRUSHES.
Check the brushes to see that they slide freely in their holders and make full contact on the commutator. If
worn to half their original length or less. they should be replaced.
ARMATURE.
1. Check the commutator for uneven wear. excessive glazing or evidence of excessing arching. If onl!
slightly dirty. glazed or discolored. the commutator can be cleaned with 00 or 000 sandpaper. If the
commutator is rough or worn. it should be turned in a lathe. (Refer to Figure 80-2.) The armature shaft should
be inspected for rough bearing surfaces and rough or damaged splines.
2. To test the armature for grounds. a set of test probes connected in series with a I 10-volt light should
be used. Touch one probe to a commutator segment and the other to thearmaturecore. If the test lamp lights.
the armature is grounded and should be replaced.
3. To test for shorted armature coils. a growler is used. (Refer to Figure 8Cb3.) The armature is placed on
the growler and slowly rotated by hand while a steel strip is held over the core so that it passes over each
armature core slot. If a coil is shorted. the steel strip will vibrate.
4. A quick check for opens can be made by inspecting the trailing edge (in direction of rotation) of the
commutator segments for excessive discoloration. This condition indicates an open circuit.
FIELD COILS.
I. Check the field coils for grounds (refer to Figure 80-4) by placing one test probe on the frame and the
other on the starter terminal. Be sure the brushes are not accidentally touching the frame. If the lamp lights. the
fields are grounded. Repair or replace.
2. Inspect all connections to make sure they arc clean and tight and inspect insulation for deterioration.
BRUSH HOLDERS.
1. To test brush holders. touch one test probe to the brush plate and the other to each brush holder.
2. The test lamp should light when the grounded brush holders are touched and should not light when
the insulated brush holders are touched.
GEAR AND PINION HOUSING.
Inspect housings for cracks and bearings for excessive wear. Remove rust. paint or grease from mounting
surfaces.
80-10-10
Page 80-07
Revised: August 9,1984
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
CARBON PILE
GROUND
STARTING MOTOR
I
Figure 80-5. KO-Load Test Hook-up
Figure 8CL6. Stall-Torque Hook-up
BENDIX DRIVE.
The Bendix Drive should be wiped clean with a dry cloth. The pinion should turn smoothly in one
direction and should lock in the other direction. Replace drive if it fails t o check a s above o r if the pinion teeth
are excessively worn o r damaged.
ASSEMBLY OF STARTING MOTOR.
I. When assembling the staning motor. always use an arbor press and the proper bearing arbor for
installing graphitized bronze and roller bearings. The Bendix shaft should have a thin film of Lubriplate x777
o r equivalent on the Bendix portion of the shaft. End play should be .005 to .OMof an inch.
2. New brushes should be properly seated when installing by wrapping a strip of 00 sandpaper around
the commutator (with the sanding side out) I- l i 4 t o I- 112 times maximum. Drop brushes o n sandpaper
covered commutator and turn the armature slowly in the direction of rotation. Dust should be blown out of the
motor after sanding.
-
NOTE
-
The spring tension is 32 to 40 o m n s with new brushes. This tension
is measured with the scale hooked under the brush spring near the
b a s h and the reading is taken or right angles to the line ojjorce
exerted by the brush spring.
PIPER AIRCRAFT
PA-32-30] /301T
MAINTENANCE MANUAL
3. Check the position of the pinion to be sure the unit will mesh properly with the flywheel ring gear. See
specifications for unit for correct dimensions. (Refer t o Starting Motor Service Test Specifications.)
I TESTING OF STARTING MOTOR.
BENCH TEST.
I. After the staning motor is reassembled. it should be tested to s n that the no-load current at a certain
voltage is within specifications as given in Starting Motor Service Test Specifications. T o make this test.
connect as shown in Figure 80-5. If current is too high. check the bearing alignment and end play to make sure
there is no binding or interference. Two or three sharp raps on the frame with a rawhide hammer will often help
to align the bearings and free the armature.
2. If no difficult!. is indicated in theabove test.astall torquetest may be made t o x e if thestartinp motor
is producing its rated cranking power. Make test connections a s shown in Figure 80-6.
3. If torque and current are not within specifications. check the seating of the brushes and internal
connections for high resistance. If these checks are made and found to be in good order. replace frame and field
assembly and retest starter.
STARTING MOTOR CONTROL CIRCUIT.
I . Inspect the control circuit wiring betwnn the battery. solenoid and manual starting su-itches for
breaks. poor connections and faulty insulation. Tighten all connections and make sure solenoid is firml!
mounted and makes a good ground connection.
2. Check the voltage loss across the switch contacts during normal starting. If loss is in excess of 0.2 \olts
per 100 amperes. the solenoid should be replaced.
3. If solenoid fails to operate when the manual starting switch is turned on or if it fails to release when the
manual starting switch is released. it should be removed and tested to specificalions. If either opening or
closing \.oltages are not t o specifications. replace the solenoid.
THlS SPACE INTENTIONALLY LEFT BLANK
Page 80-09
Revised: August 9, 1984
a
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
a
STARTING MOTOR SERVICE TEST SPECIFICATIONS.
Prestolite specifications for 12-volt starting motors installed as standard equipment on PA-32 series
airplanes are as follows:
CHART 8002. STARTIKG MOTOR SPECIFICATIONS
Motor Model
M 24222
Min. Brush Tension
Max. Brush Tension
32 oz.
40 02.
KO-Load Test @ 7S°F (Complete Unit)
Volt
Max. Amps
Min. R.P.M.
10
75
1600
Stall Torque Test
Max. Amps
Min. Torque. Ft. Lbs.
Approx. Volts
560
37.5
4.0
Pinion Position*
Drive at rest
Drive extended
1.748 in. 1.855 in.
2.388 in. 2.495 in.
r
t
-
-
*This dimension is measured from the centerline of the mounting
hole nearest the drive end head to the edge of the pinion.
J
STARTING THROUGH EXTERNAL POWER RECEPTACLE WITH AIRPLANES BATTERY
NEARLY DEPLETED.
When using a 12-volt battery for external power starting and the airplane's battery is nearlydepleted. the
following procedure should be used:
1. Disconnect the airplane's battery a t the negative terminal to prevent excessive loading of the external
starting battery.
2. Check that all of the airplane's electrical equipment is turned OFF.
3. Connect the external battery to the external power receptacle; turn master switch ON and s t a n engine
using normal starting procedure.
4. Turn master switch OFF; remove external battery, and then reconnect the battery at the negative
terminal.
5. Turn master switch OK.
80-10-1 7
Page 80.1 0
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
GRIDS 386 THRU 3B8 INTENTIONALLY LEFT BLANK
CHAPTER
TURBINES
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
CHAPTER 81 TURBINES
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
GRID
N 0.
EFFECTlVlTY
GESERAL
Engine Turbocharger
Troubleshooting
Turbocharger Nomenclature
Turbocharger Lubrication System Priming
Removal of Turbocharger
lnstallation of Turbocharger
Exhaust Wastegate Assembly
Removal of Exhaust Wastegate Assembly
lnstallation of Exhaust Wastegate Assembly
Adjustment of Exhaust Wastegate Assembly
Turbocharger Decoking
Throttle Control Stop Limits
-
81 Cont./Effec.
Page I
Revised: August 15, 1985
-
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
GENERAL.
ENGINE TURBOCHARGER.
The turbocharger system requires little attention between turbo overhauls. However. it is recommended
that the items outlined in the Inspection Report of Chapter 5 k checked during required inspection intervals.
Should trouble occur, refer to the Troubkshootin8 Tabk in this section and seek out the possible cause. Do
not break the clamp seal joining the turbine and compressor units.
TROUBLESHOOTING.
I
Troubles peculiar to the turbocharger are listed in Chart 8101 along with their probable cause and
s u ~ e s t e dremedies.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 8101. TROUBLESHOOllNG (TURBOCHARGER)
!
Trouble
Excessive noise or
vibration.
Remedy
C~UK
Improper bearing lubrication.
Supply required oil
pmsure. Clean or
replace oil line; clean
oil strainer. If
trouble persists. overhaul turbocharger.
Leak in engine intake
or exhaust manifold.
Tighten loose connections or replace manifold gaskets as necessary.
Engine will not deliver
rated power.
Dirty impeller blades.
Disassemble and clean.
Clogged manifold system.
Clear all ducting.
Foreign material lodged
in compressor impeller or turbine.
Disassemble and clean.
Excessive din build-up
in compressor.
Thoroughly clean cornp m m r assembly.
Service air cleaner
and check for leakage.
Leak in engine intake
or exhaust.
Tighten loose connections or replace manifold gaskets as neces-
saw.
Rotating assembly bearing seizure.
!
Overhaul turbocharger.
.
PIPER AIRCRAFT
PA-32-3@1/301T
MAINTENANCE MANUAL
CHART 8101. TROUBLESHOOTING (TURBOCHARGER) (cont)
Trouble
CIUK
Remedy
Waste gate butterfly not
closing.
Butterfly shaft binding.
Check karings.
Turbocharger impeller
binding, frozen or
fouling housing.
Check bearings. Replace turbocharger.
Critical altitude lower
than specified.
Waste grte valve
sticking.
Clean and free action.
Check interconnect
system from throttle to
waste gate.
Engine surges or
smokes.
Clogged induction
duct.
Check induction duct
for restrictions to
air flow.
Bootstrapping.
Operate engine within
range outlined in
operation manual.
Engine will not deliver
rated power. (cont)
-- NOTE
-
Smoke would be nonnal jf mghe kos idlcdjor a m g t d paiod
High deck pressure.
(Compressor discharge
pressure.)
Waste gate sticking
closed.
Butterfly shaft binding.
Check bearings.
Replace waste gate
valve or correct
interconnect control
rigging.
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CHART 8101. TROUBLESHOOTING (TURBOCHARGER) (cont)
Trouble
Oil in induction housing.
White exhaust.
CIUK
Remedy
Engine idks too slowturbo doesnt turn allowing oil to leak from
compressor seal.
.increase engine idle
Turbine oil bearing
check valve not
closing at engine
shut down.
Check spring actuated
check valve at turbo
oil inlet fitting.
Leaking oil seal in
turbine (coked oil
drain passages.)
Clean drain passages.
It is sometimes necessary to overhaul or
replace turbo.
Engine idles too slow,
turbo not turning.
Increase engine idle
speed to a maximum of
700 RPM, if turbo still
smokes. it must be
overhauled or replaced.
Check interconnect
control for proper
adjustment.
s p e d to a maximum of
700 RPM, if turbo still
smokes, it must be
replaced. Check interconnect control for
proper adjustment.
Note: New turbo may
smoke for a short
period of time.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART 8101. TROUBLESHOOTlNG (TURBOCHARGER) (cont)
Trouble
Wabte gate won't close
completely.
Turbine won't come up
to speed.
Cause
Remedy
Broken linkage.
Repair linkage and adjust waste gate to open
or close position.
Improper adjustment.
Rerig interconnect
control.
Worn or coked bearings.
Replace or overhaul
turbocharger.
Damage to turbine or
compressor wheel.
Replace or overhaul
turbocharger.
Exhaust leaks.
Repair leaks.
a
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
TURBOCHARGER NOMENCLATURE.
'
Many unfamiliar terms may appear on the following pages of this manual. An understanding of these will
be helpful. if not necessary. in performing maintenance and troubleshooting. The following is a list of
commonly used terms and names as applied to turbocharging.
TERM
MEANING
Supercharge
70 increase the air pressure (density)above or higher than ambient conditions.
Supercharger
A device that accomplishes the increase in pressure.
Turbo-supercharger
More commonly referred to as a "Turbocharger" this device is driven b~ a
turbine. The turbine is spun by energy extracted from the engine--exhaust gas.
Compressor
The portion of a turbocharger that takes in ambient air and compresses it
before discharging it t o the engine.
Turbine
The exhaust driven end of the turbocharger unit.
Wastegate
The wastegate is a butterfly type valve in the exhaust by-pass which.
throughout its travel from open t o closed. allows varied amounts of exhaust
pressure to by-pass the turbine. controlling its speed. hence the output of the
compression.
Ground Boosted or
Ground Turbocharged
These phrases indicate that the engine depends on a certain amount of
turbocharging at sea level to produce the advertised horsepower. An engine
that is so designed will usually include a lower compression ratio to a\oid
detonation.
Deck Pressure
The pressure measured in the area downstream of the turbo compressor
discharge and upstream of the engine throttle valve. This should not be
confused with manifold pressure.
Manifold Pressure
The pressure measured downstream of the engine throttle valve and is almost
directly proportioned to the engine power output.
If a turbocharger system is used only to regain power losses caused by
decreased air pressure of high altitude. it is considered that the engine has been
"normalized."
Overboost
An overboost condition means that manifold pressure is exceeding the limits at
which the engine was tested and FAA certified and can be detrimental to the
life and performance of the engine. Overboost can be caused b!
malfunctioning controllers or improperly operating wastegate in the
automatic system or by pilot error in a manual controlled system.
81-00-03
Page 81-06
lorutb: January 2, 1980
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
Overshoot
Overshoot is a condition of the automatic controls not having the ability to
respond quickly enough t o check the inertia of the turbocharger speed increase
with rapid engine throttle advance. Overshoot differs from overboost in that
the high manifold pmsurc lasts only for a few seconds. This condition can
usually be overcome by smooth throttle advance.
Bootstrapping
This is a term used in conjunction with turbo machinery. If you wen to take all
the air coming from a turbocharger compressor and duct it directly back into
the turbine of that turbocharger, it would becalled a bootstrap system and if no
losses were encountered, it would theomically run continuously. It would also
be very unstable because iffor some reason the turbo speed would change. the
compressor would pump more air to drive the turbine faster, etc. A
turbocharged engine above critical altitude (wastegate closed) is similar to the
example mentioned above, except now there is an engine placed between the
compressor discharge and turbine inlet. Slight system changes causedthe
exhaust gas to change slightly, which cruses the turbine speed to change
slightly. which causes the compressor air to the engine to change slightly, which
in turn again affects the exhaust gas, etc.
Critical Altitude
A turbocharged engine's wastegate will be in a partially open position at sea
level. As the aircraft is flown to high altitude (lower ambient pressures) the
wastegate closes gradually to maintain the preselected manifold pressure. At
the point where the wastegate mches its full closed position, the preselected
manifold pressure will start to drop and this is considered critical altitude.
NOTES:
1.
Refer to the latest revision of Lycoming Service Bulletin No. 369 for recommended engine inspections after any Overspeed or Overboost conditions.
819093
Pale 81-07
Revised: September 23, 1981
a
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
-118TO
-120
1. TAIL
ASSEMBLY
2 BUNKET TURBINE
3 WASTE GATE INTERCONNECT CABLE
4 OIL LINE
6 COMPRESSOR
6 AIR INTAKE
7 TURBINE SUPPORT WBE
8 CONTROL ARM WASTE GATE
S STOP SCREW
10 SPRING
-
-
-
R31
mkl
figure 8 1- 1. Ttfrbocharger installation
81-0003
P a p 81-08
Revbed: September 23, 1981
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
TURBOCHARGER LUBRICATION SYSTEM PRIMING.
Immediately prior to mounting the unit. prime the lubrication system as follows:
1. lnven turbocharger and fill center housing with new clean oil through oil drain.
2. Turn rotating assembly by hand to coat bearings and thmst washer with oil.
3. Coat threads of attaching bolts or studs with high temperature thread lubricant.
4. After installing turbocharger. flush oil through oil inlet line and ensure that line is clean and
unobstructed.
5. Fill engine and oil inlet line with new. clean lubricating oil, and connect line.
6. Connect oil return line.
I ' the turbocharger is to be instakd on 8 new or newly overhauled
engine, operate the engine with a sepurte dljilter in the oil supply
line to the turbocharger during the jht hour of tpemtion. This
must be done to ensure that no metalprticks a n cammed
jrom the
engine into the turbocharger lubrication system.
REMOVAL OF TURBOCHARGER. (Refer to Figure 81-1.)
1. Remove the engine cowling. (Refer t o Chapter 71.)
2. Remove the turbocharger compressor and turbine assembly by the following procedure:
A. Disconnect the oil supply and return lines from the center section of the turbo.
B. Disconnect the air ducts from the compressor inlet and outlet, and the exhaust system from the
turbine inlet and outlet.
C. Disconnect the tailpipe support bracket at the turbocharger and remove the tailpipe and
wastegate assembly.
D. Remove the bolts that attach the turbocharger to the mounting bracket and remove the
turbocharger assembly.
INSTALLATION O F TURBOCHARGER.
1. Position the turbocharger assembly in the mounting bnacket and secure with mounting hardware.
2. Carefully align exhaust system with the turbo inlet.
3. Carefully position the exhaust tailpipe and wastegate assembly to the turbocharger outlet.
4. Install coupling clamp and while tightening the coupling clamp nuts. gently tap around the periphen
of the couplings with a soft mallet while shaking the tailpipe. This will distribute the band tensions evenl~.
Continue tightening the clamp nuts until a torque of 40-50 inch pounds is reached on the turbocharger to
tailpipe clamp and 80-90 inch pounds on the bypass coupling. Safety the clamp nuts.
5. Connect the induction tube to the compressor outlet and the induction air filter assembly to the
compressor inlet.
6. Connect the oil supply and return lines to the turbocharger e n t e r section.
7. Install the engine cowling. (Refer to Chapter 71.)
8140-06
Page 81-09
Issued: August 15, 1985
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
EXHAUST WASTECATE ASSEMBLY.
REMOVAL OF EXHAUST WASTECATE ASSEMBLY.
I.
2.
control
3.
Remove engine cowling. (Refer to Chapter 71.)
Remove the nut. bolt and washers securing the wastegate interconnect cable bearing to the wastegate
arm.
Remove V band clamps securing wastegate to exhaust transition and tailpipe.
INSTALLATION OF EXHAUST WASTEGATE ASSEMBLY.
Install wastegate assembly with gasket between exhaust transition and tailpipe.
Secure wastegate with V band clamps and torque clamps to specifications given in Figure 8 1-1.
3. Secure the wastegate interconnect cable bearing t o the control arm with the appropriate washers. bolt
and nut.
I.
2.
-- NOTE
-
The wastqate valve should be brbrieded w&h Mouse Milk or
W D J O at the butt*
pivot points every SO hours. Mouse
Milk may be purchased from WorIdwide Aircrqft F i k a Corp.,
1685 A bram Ct., Son Leundro, CA 94577.
ADJUSTMENT OF EXHAUST WASTECATE ASSEMBLY.
The exhaust wastegate (butterfly) valve is mechanically linked t o the throttle control arm by means of the
wastegate interconnect cable. The wastegate may be adjusted as follows:
I. Remove the engine cowling as described in Chapter 71.
2 . Remove the clamp securing the tailpipe assembly to. the wastegate and separate wastegate and tailpipe assembly (separate sufficiently to allow access to the butterfly valve within the wastegate).
3. Place the throttle in the near-full open position.
4. Place the shank end of a #31 drill bit between the inner wall of the wastegateassembly and the butterfly valve (Refer to Figure 81-1.)
5 . With the throttle now in the full-open position (against the stop) a slight drag should be felt when the
drill bit is moved in an in and out motion. Should the throttle control arm not contact its stop. or should the
drill bit be too loose, adjust the interconnect cable rod end to obtain the proper clearance.
6. Place the tailpipe assembly in position and secure with the appropriate clamps.
7. lnstall upper and lower cowling as described in Chapter 71.
8. Flight test the aircraft t o determine critical altitude (16,000 + 500 feet density altitude) at take-off
power of 2700 RPM and 36 inches Hg.
9. If the above criteria is not met, further ground adjustment of the wastegate will be required.
81-00-10
Page 81-10
Revised: August 23,1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
TURBOCHARGER DECOKINC.
I
Mouse Milk lubricant may be used for decoking the turbine and compressor drive shaft by the following
procedure:
I. Disconnect the oil inlet and outlet lines from the turbocharger and aUow all oil to drain.
2. Cap the outkt port on the turbocharger.
3. Pour the Mouse Milk into the oil inlet port of the turbocharpr and rUow the unit tosoak owmight.
4. Drain all Mouse Milk from the turbocharger and flush the unit with engine oil.
5. Prime the turbocharger in accordance with Turbocharger Lubrication System Priming.
THROTTLE CONTROL STOP LIMITS.
The adjustment of the throttle control stop limits is limited t o just checking that the throttle control arm
contacts the full open stop before the turbo wastegate contacts the fully closed stop.
-- NOTE
-
Do not o&st the wastegOtC stop SMW. This is preset by the engine
mtmujac&rer to momtam .d05inch to ,015 inch clcrrmuce ktwccn
the wastegate valve md uhurrrl tube when tht tluottk isjvll cpen.
(Rcjrr to luted Lycaming S e w k Bulkth No. 118.)
-END -
Revised: February i9, 1982
a
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
~
CHAPTER
CHARTS AND WIRING
DIAGRAMS
PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
-
CHAPTER 91 CHARTS A N D WIRING DIAGRAMS
TABLE OF CONTENTS/EFFECTIVlTY
CHAPTER
SECTIOS
SUBJECT
SUBJECT
GRID
KO.
EFFECTIVITY
GENERAL
Torque
Tightening huts on Flared Tube Assemblies
Tube and Hose Assembly Torque
Flexible Hose Assemblies with Flared Fittings
Recommended Kut Torques
Decimal Conversions
Conversion Charts
Inches to Millimeters
Centigrade - Fahrenheit Conversion Table
Units of Measure
Decimal Millimeter Equivalents of Drill Sizes
List of Consumable Materials
Electr~calWire Coding
Electrical Symbols
Electrical Schematic Index
-
91 Cont./Effec.
-
Page 1
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
-
1
- -
GENERAL.
The torque values given in Chart 9102 are derived from oil-free cadmium-plated threads and are
recommended for all airframe installation procedures where torquina is required. unless otherwise noted.
Engine torque values are found in the latest revision of Lycomin~Overhaul Manual, and propeller torque
values are found in Chapter 61 of this manual. Chart 9101 lists the torque values for flared fittings of various
sizes and material.
Do not overtwque ftnin#s.
-
TIGHTENING NUTS ON FLARED TUBE ASSEMBLIES.
Nuts on metal flared tube assemblies shall be ti~htenedfinger tight and then tightened with a smooth
jawed wrench to the torque specified in Chart 9101. The fittingt shall not be lubricated.
CHART 9101. TUBE AND HOSE ASSEMBLY TORQUE
-
I
1
TORQUE INCH POUNDS
AN818
(NUT)
DASH
NUMBER
ALUMINUM
O.D.
O.D.
INCHES
TUBE*
ALUMINUM OXYGEN
TUBE (MS33583)
(DOUBLE FLARE)
STEEL
TUBE
b
MIN. MAX.
MIN.
MAX.
75
89
105
150
114
20
25
50
30
35
65
135
-5
-6
-8
51 16
318
112
70
110
230
90
130
260
170
270
450
200
-10
-12
-16
518
314
I
330
460
5OO
360
500
700
650
990
1200
700
lo00
1400
-20
-24
-32
1 114
I 112
2
800
900
1520
800
900
1800
2000
1900
2660
1680
2100
2940
-2
-3
3 i 16
-4
118
95
300
SO0
MIX.
MAX.
-----
---
-------
100
200
300
125
250
400
-----------
-------------
---
.Values for aluminum tube also apply to copper t u b . If m y element of r given connection is aluminum (nut,
sleeve, nipple, tube, etc.) the values for duminum tube shall apply.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
FLEXIBLE HOSE ASSEMBLIES WITH FLARED FI'ITINGS.
Nuts on flexible hose assemblies with flared fittings shall k tightened finger tight and then tightened with
a smooth jawed wrench in accordance with Chrn 9101. The fittings shall not be lubricated. Hoses with
aluminum fittings (nipples and nuts) shall k tightened to the minimum/ maximum values listed for aluminum
tube. Hoses with steel fittings (nipples and nuts) shall be tightened to the minimum/maximum values listed for
steel tube, except as otherwise noted in Chan 9101.
.THIS SPACE INTENTIONALLY LEFT BLANK
9141-03
Page 91-02
Added: May 21, 1980
PIPER AIRCRAFT
PA-St301/30lT
MAINTENANCE MANUAL
CHART 9102. RECOMMENDED NUT TORQUES(INCH:POUNDS)
TOROUES: The importance of comt mpliation o n not k
mmnphmizad. Undenoqw a n mlt in unnomary mrr of nu8
and bolo u mll u .the puts they n holding t q ~ t h ~ rW. m
inufficient pnrrums a n r p p l d , u n m n lads will k t m m i m d
throughout the m m b l y which m y nruh h oxadve rmr or
pmnrtun frilun due to flgue. O H ~ O ~a W
n k oqudly bmrging
m u s e of failure of a bolt or nut from anrrVlOingtha tluwded rrut.
Then m a fmr ample, but wry 'rmportmt, p m d u n r that should be
COARSE WREAD SERIES
s-I
AN 7 3 mnr AN 81
AN 173 mru AN 186
MS~OOJ~~~UMS~O(>~~
LIS 20073
MS 20074
AN 509 NUS
24694
AN 575 NU525
m 27039
NUTS
St-l Tenr~on
AN 310
AN 315
AN 363
AN 365
NAS 1021
IAS 17825
M 21045
W 10165
M S m
NAS 679
NOTE
FRlnlON DRAG TOROUE VALUES
7-
AN 3 m r u A N 30
AN 4 2 mru AN 4s
followd to r r w n that the comct torque h applied:
1. Calibnte the toque m n c h pmiodially to rrun waurry;
m d ncheck frequently.
2. Ascentin that the bolt m d nut thmads wr dean and dry
(unless othenvise specified by the nunufrtum).
3. Run nut donn to n u r c o n m with the -her
or bowing
turfre and check l r i n i o n dng torque" mquind to turn the
nut.
4. Add the friction drag toque to the dmhd toque
recommended by the manufrctunr, or obtain dsdnd toque
8s shown inchan 9102. This is n f e m d to 8s fin81 toque
which rhould regimr on the indicator or the letting for a
#18p0~tf
type wrench.
For more details on torquing, nfer to FAA Manual
AC 43.13-1A.
NUT AND BOLT SUES 8 THROUGH 7 / 1 6
WL'TS
Steel Shear
7
NAS 1022
MS 17826
US 2 0 ~ 6 4
:2
I
INCLUDE
Nutboct
mr*
SEENOTE
8
10
-32
-24
114-20
916-18
36-16
7/16-14
1/1-13
wl6-12
-11
YC10
7m- o
1
-8
1.im-a
1-1/46
Tomu. L m ~ n T oraue Llmets
on-lbs
Mln
tn.10~
MI^
M
27
m
a
30
3
80
70
140
240
150
265
330
335
400
480
700
wo
700
1.1%
2.200
1.700
s.wo
6.WO
1.600
3.000
5.000
6 . m
8.000
M
22
0
1
::g
700
3.m
4.000
X
2.1
3
55
108 j
1751
200 1
240 !
g
~
1
3
a
11s
1%
255
290
420
540
950
r .BOO
3 . a
4.000
5.m
*
91-01-04
Page 91-03
Revised: February 19, 1982
~
~
~
PIPER AIRCRAFT
PA-32.301 /30; T
*MAINTENANCE MANUAL
CHART 9102. RECOMMENDED NUT TORQUES -.
(ISCH-POUSDS) (con,.)
t
CINE TMREAD SERIES
BOLTS
S t a l Tonwon
8OLTS
# i ~ ~ ~ ~ h ~ = i o o l r
NAS 144 itwu NAS 168
AN 3 thru AN 20
AN 42 thru AN 49
AN 73 thru AN 81
AN 173 thru AN 186
MS 20033 rkru MS 20046
NASWtMuNASYO
NAS 583 Hwu NAS 680
NAS 624 itwu NAS
NAS 1303mmNAS '320
NAS 172
MS 2W73
MS 10074
I
MS 27039
AN 310
AN 315
AN 363
AN 365
NAS 1021
MS 17825
MS 21W5
MS 20365
MS 2m00
NAS 679
Torpue Lrn111
~n.lbi
12
38
IK)
160
240
550
480
1
Max
NO*
15
43
100
200
270
600
6W
1.100 1 . m
2.300
2.500
2.500 3.000
3,700
4,540
5.000 7.000
9.000 11.000
MS 270190
MS 2YlOIDO
'
NAS e
4
NUTS
Stat ~~n
stat S h u t
Alum Tenwn
AN 320
AN 364
NAS 1022
MS 17826
AN 310
AN 316
AN S 3
AN 365
AN 320
AN 36#
NAS 1022
AN SSD
AN 3 l W
NAS 10210
MS 20364
MS 17825
MS 20155
MS 21015
Ms 20364
S m l Shew
Alum Shear
AN 3100
AN 364D
NAS 1022D
MS 1 m 6
NAS 1021
NAS 679
NAS 1291
Torque L ~ m ~ t r Toraur L m l n
on-lbr
m-lbs
-
Mln
AN 3 0 0 mru AN 1000
AN 17300 thru AN 1WDD
AN 6WDD
AN 525D
NUTS
NUTS
S r n l Tms~on
BOLTS
Alurn~num
S a d f mmon
Mln
X
M
I
Mln
BOLT AND NUT'SIZES
7
8
rn
60
120
176
370
too
660
1.1.600
2,200
3,000
5.400
Toraur Ltm~ts
m-Ls
-
70
780
1.500
1.800
3.m
4.200
6.600
Max
Mln
i d THROUGH 711 6 INCLUDE FRICTIOL
110
1W
200
130
80
80
205
130
150
330
620
730
200
*00
#K)
770
sW)
490
650
760
1.2.100
2.700
3,6.800
950
1-
1
1.250
2,650 3.200
3.550 4.45W 5.500
6.000
7.100
ll.Q#),l3.r00
ToraueL~mtts
1n.1br
-
33
145
I#)
400
410
TomurLlm~tr
tn.lbr
230
2.33W
4.400
).OW
Max
1
Mln
DRAG TOROUE
I
10
3
2
33
21
6 0 7 5 4 5
125
100
65
190
155
125
300
2 0
210
280
410
160
3BO
WO
230
S50
270
070
950 1.250
560
750
1.250
1.900
950
1.600
2.400
2.100
3,100 1.250
2.3.900 6.-
Max
6
28
8 0
100
150
270
260
360
420
880
1.200
1.W
2.000
3.650
I
Revbtd: February 19, 1982
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
--
CHART 9103. DECIMAL CONVERSIONS
91-02-00
Page 91-05
Issued: Jmuuy 2,1980
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHART 9104. CONVERSIOK CHARTS
I . These charts contain the various conversion data that may be useful when figuringcapacities. lengths.
temperatures. and various weights and measures from the English system values to the metric system
values or back a p i n .
2. The English system is in use by England and the United States. All other countries use the metric
system.
3. Procedure for Convening Inches to Millimeters. (Refer to Chart 9104.)
A.
.
Example: Conven 1.5 inches to millimeters.
( I ) Read down inches column to I inches.
( 2 ) Read across top inch column to 0.5.
(3) Read down and across to find millimeters (1.5 inches to 38.10 millimeters).
4. Procedure for Convening Fahrenheit
Chart 9 104.)
A.
(OF)
and Celsius (OC) (Centigrade) Temperature. (Refer to
Read number in middle column. if in degrees Celsius (OC). read Fahrenheit equivalent in right
hand column. If in degrees Fahrenheit (OF). read Celsius equivalent in left-hand column.
91-03-00
Page 91-06
Added: May 21, 1980
PIPER AIRCRAFT
PA=3%301/3QlT
MAINTENANCE MANUAL
a
CHART 9104. CONVERSION CHARTS (am)
IWCllrS TO W U M m
/
0.00s
0.0.0~7
0.w
0.009
INCHES
0.10.194
0.101~0
0.0%
a
0.m
O.I~S
0.1~9
0.1803
0.20~7
O . ~ I
0.000
0.001
0.002
a003
0.029
0.279
0.133
1.041
0.050
0.W
0.5s
0.812
1.066
0.01
0.02
0 . m
0.15~
O.IM
0.2032
I
0.00
0.01
0.02
0.03
0.04
0.W
0.W
0.762
1.016
INCHES
0.00
o.nt
atcoo
QIW
QIIW
QZW~
alnl
alas
aim
0.21~
earn
&OW
MILUMrnR
0.0%
a101
0.3s
L#S
0.W
0.-
arm
a
oat3
0.1tor
a1616
L I ~ J O alns
0 . m
aatu
0 . ~ 3
0.~38
QW5
0.006
0.W
0.001
0.009
0.127
0.581
Qb33
0.177
0.431
0.685
0.9
1.193
0.~03
0.457
0.711
0.969
1.219
0.228
0.482
0.736
0.990
1.2U
alu~
alms
aaln
e.1~1
0.1473
o.1m
alnl
0 . 9
0 . ~ 9
-
0.1498
0.1732
0.2006
0.2260
0.214
..
o.ur
am
I
1.1 11
1.143
0.192
0.46
0.660
0.9
1.168
0.m
QW
0.M
0.07
0.08
0.09
1.m
3.810
I.=
4.W
1.m
4.318
&NO
L(D1
LU)
8.m
I
11.684
9.m
11.938
2.032
4.92
7.112
9.U2
I2192
ZZl6
4.826
1.366
9.906
12.446
.m2
0.03
o.uc
MIU1MerEa
0.0
0. I
0.2
0.3
0.4
2. W
3.080
7.610
10.18
0.254
2 .
9.334
7.874
10.414
0.3.011
9.W
(.la
I0.W
a762
3.302
2
0.016
832
8
I0.m
1
&
.
II.1N
11.00
Page 91-07
Added: May 21.1980
PIPER AIRCRAFT
PA-32-301/3@lT
MAINTENANCE MANUAL
CHART 9104. CONVERSION CHARTS (cont)
CENTIGRADE-FAHRENHEIT CONVERSION TABLE
Example: To convert W C . to Fahrenheit, find 20 in the ccnter
column headed (F-C); then read 68.0°F. in the column (F) to the
right. To convert 20°F. to Centipde; find 20 in the ccnter wlumn
and read -6.6PC. in the (C) column to the left.
C
-56.7
-51.1
45.6
40.0
-34.0
-38.9
-23.3
-17.8
-12.22
-6.67
-1.11
4.44
10.00
15.56
21.1 1
26.67
32.22
27.73
43.33
38.89
54.44
60.00
65.56
71.00
76.67
82.22
87.78
93.33
98.89
F-C
-70
-60
-50
40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
I20
130
140
150
160
170
180
190
200
210
F
C
-94.0
-76.0
-58.0
40.0
-22.0
4.0
14.0
32.0
50.0
68.0
86.0
104.0
122.0
14.0
158.0
176.0
194.0
212.0
230.0
248.0
266.0
284.0
302.0
320.0
338.0
356.0
374.0
392.0
410.0
104.44
110.00
115.56
121.11
126.67
132.22
137.78
143.33
148.89
154.44
160.00
165.56
171.11
176.67
182.22
187.78
193.33
198.89
204.44
210.00
215.56
221.11
226.67
232.22
257.78
243.33
248.89
254.44
260.00
F-C
220
230
240
250
260
210
280
290
300
310
320
330
340
350
360
370
380
390
100
410
420
430
440
450
460
470
480
490
U)O
F
428.0
446.0
464.0
482.0
S00.0
5 18.0
536.0
554.0
572.0
590.0
608.0
626.0
644.0
662.0
680.0
698.0
716.0
734.0
752.0
770.0
788.0
806.0
824.0
842.0
860.0
878.0
896.0
914.0
932.0
9163-02
Page 01-08
Added: May 21, 1980
PA-32-301 / H I T
MAINTENANCE MANUAL
CHART 9104. CONVERSION CHARTS (wnt)
MULTIPLY
BY
TO OBTAIN
CENTIMETERS
0.3937
0.0328 1
IN.
FT.
CU. CENTIMETERS
0.001
0.06102
0.0002642
LITERS
CU. IN.
U.S. GAL.
28.320
I.728
7.48 I
1.32
CU. CM.
CU. IN.
U.S. GAL.
LITERS
CU. IN.
16.39
0.0 I639
O.OM329
0.01732
CU. CM.
LITERS
U.S. GAL.
QUARTS
CU. METERS
IOOOaOO
35.314
61.023
264.17
999.97
CU. CM.
CU. FT.
CU. IK.
GAL.
LITERS
FEET
0.WW8
12.000
304.8
0.3333
METERS
MILS.
MM.
YARDS
0.1383
0.001285
0.OOWO376
M-KG
m
KW-HR
FLUID OZ.
8
29.6
DRAM
CU. CM.
GAL.. IMPERIAL
277.4
1.201
CU. IN.
U.S. GAL.
LITERS
CU.
Fr.
m.-LB.
4.W
GAL.. U.S. DRY
268.8
0.15%
1.164
4.405
CU. IN.,
CU. FT.
US. GAL.. LIQ.
LITERS
231.0
0.1337
3.785
0.8327
128
CU. Ih'.
CU. FT.
LITERS
IMPERIAL GAL.
FLUID 0 2 .
IN.
2.W
.a333
CM.
Fr.
JOULES
0.000948
0.7376
BTU
FT.-LB.
GAL.. U.S. LlQ.
LB.. AVDP
16.0
GRAMS
GRAINS
OUWCES
SQUARE INCH
6.4516
SQ CM.
POUND PER
SQUARE INCH
(PSI)
0.0703
KGCM
SQUARED
STATUTE MILE
1.KN
0.8684
KILOMETER
NAUTICAL MILE
NAUTICAL MILE
1.151
STATUTE
MlLE
QUART
.W3
LITER
MILLIMETER
1000
MICRO\
MICRON
0.00 1
O.aa0039
MILLIMETER
INCH
11.521
METER
GRAMS
0.72
METER
GRAMS
0.453
KILOCRAMS
453.6
'IIKW)
v
INCH
K)UNM
INCH
OUNCES
#)UNM
,
i
91-03-03
Page 91-09
Added: May 21, 1980
PIPER AIRCRAFT
PA-32-381/301T
MAINTENANCE MANUAL
CHART 9104. CONVERSION CHARTS (cont)
DECIMAL MILLIMETER EQUIVALEKTS OF DRILL SIZES
Doc~mrl/MillinwurEquirnbnta d Drill 8ip.r From 1/2" to No.60
Sizm Duimrl W
i
Equiv.
Equiv.
Sue him1 Miliml*
Lquiv.
Equiv.
S b 0.dmrl
wiv.
24 0.162
26 0.1485
26 0.147
61
62
1/16
63
64
0.067
0.0835
0.0625
0.0595
0.065
1.7018
1.6129
1.6875
1.5113
1.397
0.1U
0.10.1406
0.136
0.1285
3.6676
3.6719
3.6687
3.4544
3.2639
66
3/64
66
67
68
0.052
0.0468
0.0465
0.043
0.042
1.3208
1.1906
1.1811
1.0922
1.0668
0.126
0.120
0.116
0.113
0.111
3.1760
3.048
2.0181
2.8702
2.8184
69
60
61
62
63
0.041
0.040
0.039
0.038
0.037
1.0014
1.016
0.9906
0.9652
0.9398
36
7/04
36
37
38
0.110
0.1~3
0.1085
0.101
0.1016
2.704
2.ml
2.m1
2.6416
2.6781
04
66
66
1/32
67
0.036
0.035
0.033
0.0312
0.032
09144
0.899
0.8382
0.7937
0.8128
39
40
41
3/32
42
0.0996
0.088
0.096
0.0937
0.0935
2.6273
2.4892
2.4384
2.3812
2.3749
68
69
70
71
72
0.031
0.029
0.028
0.026
0.025
0.7874
0.7366
0.7112
0.8600
0.635
43 0.009
U 0.006
46 0.082
46 0.001
47 0.0786
2.2606
2.1844
2.0828
2.0674
1.8939
73
74
76
76
77
0.024
0.0229
0.021
0.020
0.018
0.6096
0.58166
0.5334
0.508
0.4572
1.1.8304
1.8642
1.778
1/64
TO
79
bO
0.0156
0.016
0.0145
0.0135
0.3969
0.4064
0.3683
0.3429
12.7#K)
12.3031
11.8062
11.6094
11.1126
G 0.261
F 0.267
E-l/4 0.260
D 0.246
C 0.242
6.6294
6.6278
6.6.2484
6.1468
6/32
0.4218
0.413
13/32 0.4062
Y 0.404
X 0.397
10.7166
10.4902
10.3187
10.2616
10.0038
B
16/64
A
1
2
0.238
0.2343
0.234
0.228
0.221
6.0452
6.S531
6.9136
6.7912
6.6131
27
el64
28
29
30
26/64 0.3906
W 0.386
V 0.377
3/8 0.375
U 0.368
9.9212
9 . W
9.5758
9.6250
9.3472
7/32
3
4
6
6
0.2187
0.213
0.209
0.2055
0.204
6.6662
5.4102
6.3086
5.2197
5.1816
1/8
31
32
33
34
0.3693
S 0.346
11/32 0.3437
R 0.339
9.1262
9.1281
8.7884
8.7300
8.6106
13/64
7
8
9
10
0.2031
0.201
0.199
0.196
0.1935
6.1694
6.1054
6.0646
4.9784
4.9149
0.332
0.3281
0.323
0.316
0.3125
8.4328
8.3337
8.2042
8.0264
7.9375
11
12
3/16
13
14
0.191
0.189
0.1876
0.185
0.182
4.8514
4.4.7625
4.699
4.6228
N 0.302
99/64 0.2968
M 0.295
L 0.290
9/32 0.2812
7.6708
7.5387
7.4930
7.3660
7.1425
15
16
17
11/64
18
0.10
0.177
0.173
0.1718
0.1696
4.672
4.4958
4.3942
4.3656
4.3053
0.281
0.277
0.272
0.266
0.2656
7.1374
7.0358
6.9088
6.7664
6.7462
19
20
21
22
0.166
0.161
0.169
0.157
4.2164
4.0894
4.0306
3.9878
27/64
Z
23/64
1 0.358
Q
21/64
P
0
6/16
Sue Decimal M i l f m ~ r
Equlv.
Eguiv.
3.8687
3.8116
3.3.7973
3.7338
0.W
0.4843
0.4687
0.4631
0.4375
112
31/64
16/32
29/64
7/16
MYmrrrr
Equiv.
0.1682
13 0.164
I
K
J
1
H
17/64
6/64
48
49
50
0.0781
0.076
0.073
0.070
DRILL SEES AVAILABLE.
Drill may k abtacnd n regular rims to a 4 inch diamotrr. and i w e a n in 64thsof an inch.
The rogulrr nwtrcc drills vary from 2 to 76mm. and t m r u in 0.5mm. nrrattons
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEFT BLANK
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS
MATERl AL
SPEClFlCATlON
PRODUCT
VENDOR
ABS-Solvent I Cements
Solarite, #I I Series
Solar Compounds Corp.
Adhesive
EC 801
Minnesota Mining and
Manufacturing
Adhesive Coatings and
Scakrs Division
EC 807
EC 1357
E C 1300L
Scotch Grip 22 10
(Rubber-Adhesive)
Proco #6205 1
Protective Coatings. Inc.
Anti-Galling
Solution
MI L-A-907
Eascsff
Taxacone Company
Anti-Seize Compound
(Graphite Petrolatum)
M IL-T-5544
Armite Product
Armite Laboratories
Anti-Seize Compound
Royco 44
Exxon Oil Company
Royal Lubricants Co.
Armite Product
Annite Laboratories
Anti-Seize Compound
(White Lead Base)
TT-A-580
(JAS-A-669)
I
1
I
Fel-Pro Incorporated
Anti-Seize Thread
Compound "HIGH
TEMPERATURE"
Fel-Pro CS-A
Buffing and Rubbing
Compound S
Adomotive TypeDu Pont #7
Dupont Company
Ram Chemical #69
Ram Chemicals
Compound for
Polishing
Mirror Glaze
Mirror Bright Polish Co..
Incorporated
Cleaners
Fantastic Spray
Perchlorethylene
VMBP Naptha
Light Fluid
Local Supplier
M S-122-6075
Local Supplier
Dry Lubricant
Rourocarbon Release
Agent
I
I
I
M 1L-L-60326
*Vendor information (manufacturer, address and phone) may be found at the back of Chart 9105.
I
Revised: ~ugust-9,1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
b
MATERIAL
SPECIFICATIOK
PRODUCT
VEKDOR*
Epoxy Patching
Compound
Solarite No. 400
Solar Compounds Corp.
Gasket Cement
Permatex No. 2
Permatex Company. Inc.
Grease. Actuator
2 196-74- 1
Dukes Astronautic5 Co.
Supermil Grease
KO. A72832
Amoco
Royco 27A
Royal Lubricanteo.
Shell 6249 Grease
Shell Oil Company
R R-28
Socony Mobil Oil Co
Castroleax A l
Burmah-Castrol LTD.
Grease. Aircraft
Instrument. Gear
and Actuator Screw
(Temp. Range - 100' F
to +250°F)
MI L-G-23827A
(See Kote I )
Low-Temp Grease E.P. Texaco Incorp.
Grease Aircraft
Instrument. Gear
and Actuator Screw
(Temp. Range-65' F
to +250°F)
M 1L-G-3278
51 14 E.P. Grease
AV 55
Standard Oil of Calif.
Aeroshell Grease 7
Braycote 627s
Mobil Grease 27
Shell Oil Compan)
B.P. Aero Grease 31B
B.P. Trading Limited
Unitemp E.P.
Texaco Incorporated
RPM Aviation
Grease 5.
Supermil Grease
KO. 8723
Standard Oil of Calif.
Mobil Oil Corporation
'Vendor informat~on(manufacturer. address and phone) maybe found at the back of Chart 9105.
b
9 1-04-00
Page 91-12
Revised: August 9, 1984
PIPER AIRCRAFT
F'A-32-301/301T
MAINTENANCE MANUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
MATERIAL
SPECIFICATION
Grease, Aircraft
Instrument. Gear
and Actuator Screw
(cont)
Grease Ball and
Roller Bearing
Grease. General
Purpose. Wide
Temperature
M 11-G- 18709
MI L-G-8 1322
PRODUCT
-
VENDOR*
Aeroshell Grease 7A
Shell Oil Corporation
Royco 78
Royal Lubricants
Company
L-I212
Sinclair Refining Co.
1916 Uni-Temp
Grease
California-Texas Oil
Corporation
Regal ASB-2 Formula
TG- 10293
Texaco Incorporated
Andok B
Exxon Company. USA
Code 1-20481. Darina
Grease 1 XSG-6213
Code 71-501. Darina
Grease 2 XSG-6 152
Code 7 1-502. Alvania
Grease 2 XSG-615 1
Code 7 1412, Cyprina
Grease 3 XSG-6280
Code 7 1-003
Shell Oil Company
Marfak All Purpose
Texaco lncorporated
Aeroshell No. 6
Shell Oil Company
Mobil Grease 77
or Mobilux EP2
Mobil Oil Corporation
Shell Alvania EP2
Shell Oil Companv
Royco 22
Royal Lubricants Co.
Mobil Grease 28
Mobil Oil Corporation
Aeroshell No. 22
Shell Oil Company
Vendor information (manufacturer, address and phone) may be found in back of Chan 9105.
I
91-04-00
Page 91-13
a
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
--
-
-
-
-
-
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
h
MATERIAL
Grease. High
Temperature
SPECIFICATION
MI L-G-3U5
PRODUCT
High Temp. Grease.
Marfak All Purpose
VENDOR'
Texaco incorporated
Shehire Grease HT.
Shell Oil Co.
Alvania E. P. Grease 2,
Aeroshell Grease 5
Grease Aircraft
General Purpose
Grease. Lubricating.
Molybdenum
Disulfide. Low and
High Temperature
Greasing. Lubricating.
Plug Valve. Gasoline
and Oil Resistant
MIL-G-77 1 1
M1L-G-2 1 164
MIL-(3-6032
MIL-G-6032
Greasc 77, Mobilux
E.P. 2
Mobil Oil Corporation
Royco 45A
Royal Lubricants Co.
1-1231
Sinclair Refining Co.
Regal AFB2, Regal
Starfak Premium
Texaco Incorporated
PED 3040
Standard Oil of Calif.
Aeroshell Grease 6
Shell Oil Co.
Royco 11
Royal Lubricants Co.
Aeroshell Grease
No. 17 ,
Shell Oil Co.
Royco 64C
Royal Lubricants Co.
Castrolease MSA (c)
Burmah€astrol LTD.
Royco 32
Royal Lubricants Co.
Castroleasc PV
Burrnah-Castrol LTD.
Parker Fuel Lube 44
Parker Seal Company
B.P. Aero Grease 32
B.P. Trading Limited
1237
Lehigh-Tenneco
Chemicals Co, Inc.
Rockwell950
Rockwell International
- --
'Vendor information (manufacturer. address and phone) may be found at the back of Chan 9105.
PIPER AIRCRAFT
PA-32-361/301T
MAINTENANCE MANUAL
-
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
I
MATERIAL
SPECIFICATION
PRODUCT
Aem Lubripkte
Grease, Waterproof
High and Low
Temperature
"Hot Melt" Adhesive
Polyamids, and "Hot
Melt" Gun
Stick Form
H in. diameter.
3 in. long
Hydraulic Fluid
MIL-H-5606
(Univis 40)
VENDOR8
Fiske Brothers
Refining Company
Sean, Roebuck and
Company or most
hardware stores.
Brayco 756D
Bray Oil Company
TL-5874
Texaco Incorporated
PED 3565
Standard Oil Company
of California
Aircraft Hydraulic
Oil AA
Tcxaco Incorporated
RPM Aviation Oil
No. 2 Code
PED 2585
PED 3337
Standard Oil Company
of California
3126 Hydraulic Oil
(Univis 40)
Exxon Company. USA
Aeroshell Fluid 4,
St-7694
Shell Oil Co.
Aero H F
Mobil Oil Corporation
Royco 756, 756A
and 756B
Royal Lubricants Co.
lsopropyl Alcohol
Fed. Spec. TT-1-735
Local Supplier
lsocryl Tape
(PM S-C 1012-2)
Schnec Moorhead
Chemicals, Incorprated
Kevlar
Kevlar
Kevlar Special Products
*Vendor information (manufacturer, address and phone) may be found at the back of Chan 9105.
Revised: ~ u t u s t 9 1984
.
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
k
MATERlAL
SPECIFICATION
PRODUCT
VENDORL
I
Leak Detect or
Solution for
Oxygen Systems
Loctite
MIL-L-25567
Alpha 73
U.S. Gulf Corporation
Oxygen Leak Detector
Type 1
Leak Tec # I M ) X
American Gas and
Chemical Co. LTD
M 11-S-22473
Grade AA
m i t e 290
Loctite Corporation
MIL-S-22473
Grade H and HV
Loctite 222
Methylethylketone
Fed. Spec. 'IT-M-26 1
Molybdenum
Disulfide
MIL-M-7866
Local Supplier
-
Molykote Type G
(Pane)
Dow Coming Co.
Molykote-Type 2
(Powder)
Oil, Air Conditioner
Oil Lubricating.
General Purpose
Low Temperature
MIL-1-7870
Frigidairc #525
Virginia Chemical
Suniso #5
Sun Oil Company of
Pennsylvania
Texaco Capilla "E"
Texaco Incorporated
Caltex Low Temp.
Oil
Caltex Oil Products
Company
Sinclair Aircraft
Orbit lube
Sinclair Refining
Company
1692 Low Temp Oil
Texaco lncorporated
Aviation Instrument
Oil
Standard Oil Company
of California
Royco 363
Royal Lubricants Co.
*Vendor information (manufacturer, address and phone) may be found at the back of Chan 9105.
PIPER AIRCRAFT
PA-32-31 /3011'
MAINTENANCE MA.NUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
I
MATERIAL
SPEC1FICATION
PRODUCT
VENDORa
Repcon
Unelco Corporation
Safety Walk.
Pressure Sensitive
Flextred 3W
Wooster Products.
Incorporated
Sealant
PRC jOOO
Products Research
Company
Sealant, Fuel
Tank Sealing
RS-Xb, Stripper
(thin)
CEE BEE Chemical Co.
Rain Repellant
FSCM 50159
RS-24b, Stripper
(thick)
PR 1422 A-2 Sealant
(Brushing consistency)
Products Research
Company
PR 1422 B-2 Sealant
(Trowling consistency)
!
PR 1422 CL2 Sealant
PR 1431G, Faying
Surface Seal, Type 1
I
PR 1321-B!4,
Access Panel
Sealant
I
i
PA 1560 MK, Primer
(Anti-Bacteriological
Coating)
Products Research
Company
BJO-0930. Phenolic
Balloons
Union Carbide Plastics
Division
ERL-2795, Epoxy
Resin
22LA4340
Polyamid Hardener
*Vendor information (manufacturer. address and phone) may be found at the back of Chart 9105.
Revised: ~ u g u s9.
t 1984
PIPER AIRCRAFT
PA-32-301 / 301T
MAINTENANCE MANUAL
CHART 9105. LIST O F CONSUMABLE MATERIALS (cont)
MATERl AL
SPECIFICATION
PRODUCT
VENDOR*
I
Sealant. Fuselage
Structure
Class A-%. A-2.
B-2. B-4. 8-6. B-8
H.S. Bancroft Corp.
EC 1239
Minnesota Mining and
Manufacturing,
Industrial Specialties
Division
EC 612 (Leak Marker
or Weathentripping,
etc.)
B-%. B-$5, B-2,B-4,
-
G.E.-SS-4004 (Primer)
RTV-88 with
RTV-98 1 1
General Electric
Silicone Products
Depanment
PR 1221
Products Research
Company
I
I
B-8, B-12
I
I
Sealing Compound
Gasket and Joint
"Tite-Seal"
Radiator Specialty Co.
Sealer
PR 1321 B!4
Products Research Co.
DC4, DC-6
Compound
Dow Coming
G-624
General Electric Co.
Silicone Products
Depanment
Methylethyl Ketone
Methylene Chloride
Acetone
Local Suppliers
Y2900
Union Carbide: Plastic
Division
I
Silicone Compound
MI L-S-8660
(MI L-C-2 1567)
Solvents
Fed. Spec. PD 680
Type I Stoddard
Solvent
-
-
Type I1 High
Temperature
Local Supplier
Local Supplier
'Vendor information (manufacturer, address and phone) may be found at the back of Chan 9105.
91-0400
Page 91-18
Revised: August 9. 1984
I
PIPER AIRCRAFT
PA-32-381 /MlT
MAINTENANCE MANUAL
1
CHART 9105. LIST OF CONSUMABLE MATERIALS (cont)
I
MATERIAL
SPECIFICATION
Toluol
TT-M-26 1
Trichlorcthylene
MI L-T-7003
Teflon Tape
PRODUCT
VENDOR*
Local Supplier
Perm-A-Clor
Dcxtrex Chemical
Industries, Inc.
Turco 4217
Turco Products. Inc.
Minnesota Mining and
Manufacturing Company
.003' x .5" wide/-l
Shamban W.S. and Co.
Johnson & Johnson. Inc.
Permacel Division
.003" x .25" widel-2
Thread Solvent
for High Pressure
Oxygen System
M 1L-T-27730
Pennacel412
Johnson & Johnson. Inc.
Pennacel Division
Vinyl Foam
1 in x % in.
530 Series, Type 1
Norton Tape Division
Vinyl. Foam Tape
118 in. x 1 in.
5 10 Series. Type I1
Norton Tape Division
Vinyl. Black Plastic
2 in x 9 mil. andlor
1% in. x 9 mil.
Norton Tape Divsion
Note I: Take precautions when using MIL-G-23827 and engine oil. These lubricants contain chemicals
harmful to painted surfaces.
*Vendor information (manufacturer, address phone) may be found at the back of Chart 9105.
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
--
CHART 9105. LlST OF CONSUMABLE MATERIALS (cont)
VENDOR INFORMATION
A
American Gas and
Chemical Co. LTD
220A Pegasus Avenue
Nonhvale, New Jersey 07647
20 1-767-7300
Amoco Chemicals Corp.
200 E. Randolph Drive
Chicago, Illinois 6060 1
3 12-856-3200
Armite Laboratories
1845-49 Randolph Street
10s Angeles. California
9000 1
2 13-587-7744
B
BP Irading Lim~ted
Moore Lane
Brittanic House
London E.C. 2
England
I
Bray Oil Company. lnc.
9550-T Flair Drive
El Monte. CA 9173 1
213-575-1212
-
Burmah Castrol LTD
Continental Plaza
Hackensack. N.J. 0760 1
- -
C
California Texas Oil
Corp., 380 Madison Avenue
New York. New York 10017
Caltex Oil Products Co.
New York, New York 10020
CEE BEE Chemical Co.
9520 E. CEE BEE Drive
P.O. Box 400
Downey, California 9204 1
Corrosion Reaction
Consultants. Inc.
Limekin Pike
Dresher, PA 19025
.
,
Crawford Fitting Company
29500 Solon
Solon, Ohio 44 139
216248-4600
D
Dextrex Chemical
Industries Inc.
P.O. Box 502
Detroit. Michigan 48232
Fiske Brothers
Refining Company
129 Lockwood Street
Newark, New Jersey 07 105
20 1-589-9 150
.
H
H.S Bancroft Corp.
2 Rockhill Industrial Park
Cherry Hill, New Jersey 08003
8000
J
Perrnacel, Divis~onof
Johnson k Johnson, lnc.
U.S. Highway 1
New Brunswick. N.J. 08903
201-424-0400
Dow Corning Corporation
Alpha Molykote Plant
64 Harvard Avenue
Stanford, Connecticut 06902
Dukes Astronautics Co.
7866 Deering Avenue
Canoga Park, California
9 1304
E
E.1. UuPont de
Nemours & Co., Inc.
Textile Fibers
Department
Centre Road Building
Wilmington, Delaware' 19898
302-999-3 156
Exxon Oil Company
1251 Avenue of the Americas
New York, New York I0020
3 2 757 1200
- -
F
Fel-Pro Incorporated
7450 N. McCormick Blvd.
P.O. Box CI 103
Skokie, Illinois 60076
312-761-4500
G
General Electric Co.
Silicone Products Dtpt.
, Section TR-75
Waterford, New York 12 188
K
'
Kevlar Specml Products
E.1. DuPont de Nemours
and Company, Inc.
1007 Market Street
Wilmington, Delaware 19898
302-774- 1000
L
Lchigh Tenneco Chemicals
Co., Inc.
Chestenown, Maryland 2 1620
301-778-1991
-
Locktite Corporation
999 N. Mountain Road
Newington. Conn. 06 1 1 1
800-243-88 10
or
800-842-8684 (Conn. Only)
Revised: ~ u p s t 9 1984
,
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
CHART 9105. LIST OF CONSUMABLE MATERIALS (cont)
VENDOR INFORMATION
M
Minnesota Mining and MFG.
3M Center
St. Paul, Minnesota 55144
612-733-1 110
Mirror Bright Polish Co., Inc.
lrvine Industrial Complex
P.O. Box 17177
Irvin. California 927 13
7 14557-9200
Mobil Oil Corporation
150 E. 42nd Street
New York, New York 10017
2 12-883-4242
IS
Nonon Tape Divis~on
Department 66 10
Troy, New York 12181
,
Ram Chemicals Div.
210 E. Alondra Blvd.
Gardcna, California 90248
213-321-0710
Standard Oil of California
225 Bush Street
Sln Fnncisco. Calif. 94104
415-894-7700
Rockwell International
Flow Control Div.
400 N. Lexington Avenue
Pittsburgh, PA 15208
4 12-247- 3200
Sun Oil Company of Penna.
1608 Walnut St.
Philadelphia. PA 19103
2 15-972-2000
T
Taxacone Company
P.O. Box 10823 TR
Dallas, Texas 75208
S
Schnee Moorhead Chemicals
Inc.
Parker Seal Company
17325 Euclid Avenue
Cleveland. Ohio 44 1 12
21653 1-3000
Shamban W.S. and Co.
11543 W. Olympic Blvd.
Los Angeles, Calif. 90064
2 13-879-2270
Permatex Industrial
705 N. Mountain Rd.
Newington. CT 061 1 1
203-527-52 1 1
a
Products Research Co.
5246T San Fernando Road
Glendale. Calif. 9 1203
2 13-240-2060
i
Solar Compounds Corp.
I201 W. Blancke Street
P.O.Box 227
linden. New Jersey 07036
20 1-862-28 13
Royal Lubricants Co., Inc.
River Road
East Hanover, N. J. 07936
P
Protective Coatings. Inc.
805 N. Fremont Avenue
Tampa, Florida 33606
8 13-253-538 1
R
Radiator Specialty Co.
Dept T, P.O. Box 34689
Charlotte, N.C. 28234
707-377-6555
Shell Oil Company
One Shell Plaza
Houston, Texas 770002
713-241-6161
Sinclair Refining Co.
600 Fifth Avenue
New York, New York 10020
'
Socony Mobil Oil Co.
Washington 5, D.C. 20005
.
Texaco, Inc.
2000 Westchester Avenue
White Plaines, N.Y. 10650
914-253-4000
Turco Products Inc.
24600 S. Main Street
P.O. Box 6200
Carson, California 90749
2 13-835-82 1 1
U
U.S. Gulf Corp.
P.O. Box 233
Stony Brook, N.Y. 1 1790
(2 12) 683-922 1
Unelko Corporation
727 E. 110th Street
Chicago, Illinois 60628
-
Rtvbd: Augurt9, 1984
PIPER AIRCRAFT
PA-22-301/301T
MAINTENANCE MANUAL
CHART 9105. LIST OF CONSUMABLE MATERlALS (cont)
VENDOR INFORMATlON
Union Carbide: Plastic Div.
270 Park Avenue
New York. New York 10017
2 12-55 1-3763
I
C'
Virginia Chemicals. I nc.
3340 W. Norfolk Rd.
Portsmouth. Virginia 23703
804-483-7000
H'
Wooster Products. Inc.
Loehr & Wyant Sts.
Wooster. Ohio 4469 1
2 16-262-8065
PIPER AIRCRAFT
PA-32-301/MlT
MAINTENANCE MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
a
CHART 9106. ELECTRICAL WIRE CODING
C
CIRCUIT FUNCTION LETTER
WIRE NUMBER
WIRE SEGMENT LETTER
WIRE GAUGE
-
CIRCUIT FUNCTION
LEITER
CIRCUITS
A
AUTOPILOT
C
CONTROL SURFACE
E
ENGINE INSTRUMENT
F
FLIGHT INSTRUMENT
G
LANDING GEAR
H
HEATER VENTILATING & DEICING
L
LIGHTING
P
POWER
Q
FUEL & OIL
RP
RADIO POWER
RG
RADIO GROUND
RZ
RADIO AUDIO & INTERPHONE
-
J
IGNITION
W
WARNING
K
STARTER
PIPER AIRCRAFT
PA-32-31 /301T
MAINTENANCE MANUAL
CHART 9 107. ELECTRICAL SYMBOLS
CW3
BATTERY
BUS BAR
KNIFE CONNECTmS
SWITCH
S T w L
PUSH
P=
%TYPE
k v m
- PULL
CIGAR
ALTERNATOR
BEACON
THERMAL
SWITCH
PWENNlC
-
PRESS. N.C.
OR
VACUUM IJ.0.
4
ZENER
DlODE
DIODE
A
h
1
-
-
POTtNTlOklEf ER
TERMINAL BLOCK
PRESS. N.O.
OR
LAMP
-
VIEUUM N.C
FUSE
RESISTOR
GROUND
n
I
-I-
CONNECTORS
NOISE
FILTER
COJDUCTORS
SHIELDED COIDUCTORS
SWITCH
PUSH-BUTTON
SWITCH
II
SHIELDED
CONNECTOR
-.CONDUCTORS CROSSINGS AND JUNCTIONS OF CONDWTORS.
THE DOT AT THE INTERSECTION INDICATES A X)INING OF
CONDUCTORS
VALVE
91-0600
Page 91-24
Revised: Aupst 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
ELECTRICAL SCHEMATIC INDEX
FIGURE YO.
SCHEMATIC
GRlD NO.
ANNUNCIATOR SYSTEMS
Annunciator Panel
PA-32-301 : S IN'S: 32-8006001 to 32-8 106087
S IN'S: 32-8 106088 and up
PA-32-301T: S Ws: 32-8024001 to 32-8 124030
S :N's: 32-8124031 and up
COMFORT SYSTEMS
Cigar Lighter
PA-32-30 1 :30 IT
DEICE SYSTEMS
Pitot Heat
PA-32-301 :
PA-32-301T:
Pitot Static Heat
PA-32-301 :
PA-32-3OIT:
S :N's: 32-8006001 to 32-8006076
SiN's: 32-8024001 to 32-8024035
S IN'S: 32-8006077 and up
S!N's: 32-8024036 and up
ELECTRICAL SYSTEMS
Alternator and External Power Option
PA-32-301 : S N's: 32-8006001 to 32-8006076
S IN'S: 32-806077 to 32-8 106087
S IN'S:32-8106088 and up
PA-32-30 1T: S I N's: 32-8024001 to 32-8024035
S IN'S: 32-8024036 to 32-8 124030
S ;N's: 32-8 124031 and up
Avionics Master and Emergency Bus Switches
PA-32-30 1 (Optional)
PA-32-30 IT (Optional)
'
ENGINE SYSTEMS
Starter I Magneto
PA-32-301 : S IN\: 32-8006001 to 32-8 106087
PA-32-30 1 : S IN'S: 32-8 106088 and up
PA-32-30 1T: S IN'S: 32-8024001 to 32-8 124030
SIN\: 32-8124031 and up
ENVIRONMENTAL SYSTEMS
Air Conditioning
PA-32-301 !301T
Vent Blower
PA-32-30 1 1301T
-
91 Elec. Sch. Index
Page 1
Revised: August 9, 1984
-
PTPER AIRCRAFT
PA-42-301 /301T
MAINTENANCE MANUAL
ELECTRICAL SCHEMATIC INDEX (cont)
FIGURE NO.
SCH EM ATlC
I
GRID NO.
FUEL SYSTEMS
9 1-28.
9 1 -29.
Fuel Pump
PA-32-301
PA-32-30 IT
INDICATORS
Annunciators (See Annunciator System)
Clock-Analog (Standard)
PA-32-30 I
PA-32-30 1T
Clock-Analog or Digital (Optional)
PA-32-301: S N's: 32-8 106088 and up
PA-32-30 IT: S IN'S: 32-8 124031 and up
Engine Instruments
PA-32-301 Early Models
S IN'S: 32-8 106100 and up
PA-32-301T Early Models
S IN'S: 32-8 124038 and up
H ourmeter
PA-32-30 I
PA-32-30 1T
Turn and Bank
PA-32-30 1 : S 'N's: 32-8006025 to 32-8006076
S WS: 32-8006077 to 32-8106087
SlN's: 32-8106088 and up
PA-32-3OIT: S IN'S: 32-8024017 to 32-8024035
S :N's: 32-8024036 to 32-8 124030
S IN'S: 32-8 124031 and up
-
-
91-42.
9 1-42.
91-43.
91-43.
9 1-44.
-
LIGHTING EXTERNAL
Anti-Collision Wing Strobe Only
PA-32-30 1 : S IN'S: 32-8006001 to 32-8006076
PA-32-30 IT: S /N's: 32-8024001 to 32-8024035
Anti-Collision Wing Strobes and Optional Beacon
PA-32-30!: SIN'S: 32-8006077 and up
S IN'S: 32-8024036 and, up
Landing Light
PA-32-301 !301T
Navigation-Integrated with Dimmer Control
Assembly below
-
3E4
3E4
-
3E4
3E4
3E4
-
91 Elec. Sch. Index
-
Page 2
Revised: August 9, 1984
-
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
ELECTRlCAL SCHEMATIC INDEX (cont)
FIGL'RE NO.
SCHEMATIC
GRID NO.
-
LIGHTING INTERNAL
Cabin
PA-32-301: S NS: 32-8006001 to 32-8 106087
S IN'S: 32-8106088 and up
PA-32-30 IT: Early Models
SIN'S: 32-8120431 and up
Instrument. Navigation. Radio and Dimmer
Control Assembly
PA-32-30 I: S IN'S: 32-8006001 to 32-8006076
S INS: 32-8006077 to 32-8 106087
S ~N's:32-8106088 to 32-8106098
S 1 NS: 32-8 106099 and 32-8 106100
and up
PA-32-301T: S N's: 32-8024001 to 32-8024035
S N's: 32-8024036 to 32-8 124030
S ' WS: 32-8 124031 to 32-8 124046
S N's: 32-8224001 and up
Passenger Reading (PA-32-301!30 IT)
Early Models
Later Models
WARNING SYSTEMS
Stall
PA-32-30 1 30 1 T
-
91 Eltc. Sch. Index
Page 3
Rtviscd: August 9. 1984
-
PIPER AIRCRAFT
PA-32-301/3dIT
MAINTENANCE MANUAL
THIS PACE INTENTIONALLY LEm BLANK
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 9 1- 10. Annunciator (PA-32-301) SIN'S: 32-8006001 to 32-8 106087
PIPER AIRCRAFT
PA-32-301 13011
MAINTENANCE MANUAL
f~I02
W34
W
O
AYNUWCLITOII
HWtL
rrrr
>0
ir
Go2
9 AMP
\
snurr
OIL CRUsClllE
s c m amtcn
LltCM
--
-
-
-
aIItILR1
Figure 91- 1 1. Annunciator (PA-32-301) S /Ws: 32-8106088 and up
Revbed:
r up st-9, 1984
PIPER AIRCRAFT
PA-32-31 1301T
MAINTENANCE MANUAL
Figure 9 1- 12. Annunciator (PA-32-301T) S / Ws: 32-8024001 to 32-8 124030
PIPER AIRCRAFT
PA-32-301 13011
MAINTENANCE MANUAL
Figure 91- 13. Annunciator (PA-32-301T) SIN'S: 32-8 121031 and up
PIPER AIRCRAFT
PA-32-301 /MlT
MAINTENANCE MANUAL
EL 920
38607
38634
STARTER a ACC
(CIGAR LOMTEAI
THIS SPACE INTENTIONALLY
LEFT BLANK
SEE DIMMER CWTROL
SEE s r A n r E a
CIGAR
SOLENOID
-
I
Figure 91- 14. Cigar Lighter (PA-32-3011301T)
b
EL 013
3S607AB
EL 913
30607
38630
HEAT SWITCH
ClTOT/SlATlC
HEAT SW ltcn
NOTE:
FOR PA-SZ-ml. SIN'S.32810WE8 AND UP; PA-323017. SIN'@:32-8124031
AND UP.
PA-32-301 SIN'S
PA-32-3011SIN'S
32-8020001 TO 32-8024035
a
Figure 9 1- 15. Pitot Heat (PA-32-301/301T)
Figure 91-16. Pitot / Static Heat (PA-32-301
S / N's: 32-8006077and up; PA-32-30 1 T,
SIN'S:32-8024036 and up)
91-07-00
Page 91-29
Revhed: August 9,1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
.
*ILL0 9 A M P
I
I
I
I
-
d
I
I
I
I
I
I
I
+
I
-
10 ANNUWCIAIOII
I
I
I
I
I
I
I
I
I
I
I
I
I
I
-
L ,- -
- ---- - - -I
I
I
I
1
i
-Figure 9 1- 17. Alternator1External Power (PA-32-30 1)
SIN'S: 32-8006001 to 3218006076
PIPER AIRCRAFT
PA-32-31 /301T
MAINTENANCE MANUAL
Figure 9 1- 18. Alternator/ External Power (PA320301)
SIN'S: 32-8006077 to 32-8 106087
PIPER AIRCRAFT
PA-32-301 /MlT
MAINTENANCE MANUAL
UtERWTOII
FIELD I u p
-I/-'
-
NARC0 RADIO I M f f A U A t I O I I
-Nf
mWrwUOwlrYi
TO
.LYETER
ALILIUIQI
m C E
COItR ULAT
cwnoalme CIRCUIT
-
Figure 9 1 19. Alternator / External Power (PA-32-30 1)
S/N's: 32-8106088 and up
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
I
-
I
I
,
,
,
,
,
,-----
J
L -------------a,--
I
I
I
I
-
h+
-
I
I
I
I
1
I
I
I
- - - - - - - - - - 3
I
I
OPTlOrU
I
EXTERML
--
I
I
I
I
I
I
I
I
EXTERNAL
I
I
I
--
I
I
I
I
I
I
I
< r l 0 *TO
1
I- ur=%!L=SL
IYTERLOC*
---- -- - - -- -
--
STARTER
UKLllDlD
r----------.-I
I
L
,,
,,
m-
-
1
ALILlllllTm 10URQ
~
4
J
-Figure 91-20. Alternator/Externrl Power (PA-32-301T)
S / N's: 32-802400 1 to 32-8024035
91-07-00
Pact 91-33
Revbed: August 9, 1984
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
Figure 9 1-2 1. Alternator External Power (PA-32-30 1 T)
S IN'S: 32-8024036 to 32-8124030
PIPER AIRCRAFT
PA-32-301 /SO1 T
MAINTENANCE MANUAL
EL*%
YIO'
--
TO
CLOCK OCTlmS
M O U METER O C T I W
WRCO R U I O INSTALLATIOW
TO
I
Figure 9 1-22. Alternator/ External Power PA-32-30 1 T
SIN'S: 32-8 124031 and up
I
91-07-00
Page 91-35
Rwbed: Augud 9, 1984
PIPER AIRCRAFT
PA-32-301 / M I 1
MAINTENANCE MANUAL
Figure 91-23. Avionics Master and Emergency Bus Switches
PA-32-30 1 1301T (Optional)
THIS SPACE INTENTIONALLY LEFT BLANK
91-07-00
P8tt 91-36
Rwbd: August 9.1984
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
Figure 9 1-24.Starter PA-32-301 SIN'S: 32-8006001 to 32-8106087
PA-32-301TSIN'S: 32-8024W1to 32-8124030
Figure 91-25. Strner PA-32-301SIN'S:32-8106088and up
PA-32-3011SIN'S:32-8124031 m d UP
91-07-00
Past 91-37
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-M1/301 T
MAINTENANCE MANUAL
Figure 91-26. Air Conditioning (PA-32-301) SIN'S: 32-8006077 and ul
(PA-32-301 T) SI N's: 32-8024036 and up
91-07-00
PI~C
91-38
Revbtd: Au#usl9,1984
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
.
THIS SPACE INTENTIONALLY
LEFT BLANK
Figure 9 1-27. Vent Blower (PA-32-301 1301T)
Figure 9 1-28. Fuel Pump (PA-32-301)
Figure 91-29. Fuel Pump (PA-32-30lT)
91-07-00
Pate 91-39
Revised: August 9, 1984
PIPER AIRCRAFT
. PA-32-301 /SO1T
MAINTENANCE MANUAL
Figure 91-30. Clock (PA-32-301) (Early Models)
Figure 91-31. Clock (PA-32-30121 (Early Models)
I-
MASTER SOLENOID
CLOCK IWTl
X)roll.RYIIu.rr
1 0 1 - ' C Y U M
Figure 91-32. Am108 md Digital Clock Options
PA-32-301 S/N's: 32-8106088 md up
PA-32-NIT SIN'S:32-8124031 and up
91-07-00
P81t 91-40
Revised: A u p n 9.1984
PIPER AIRCRAFT
PA-32-3011301T
MAINTENANCE MANUAL
PIPER AIRCRAFT
PA-32=381/301T
MAINTENANCE MANUAL
amn
-7
TCUP
LE~T
nlwr
MAIN
YUN
IIOUTDDI
-I---
-
3
-
CIIN8Dl
SENDER
NOTE
'10 ALTERN F E U CIRCUTT
Figure 91-36.Engine Lnrt~mcnu(PA-32-MlT,S/N's: 32-8124038and up)
91-07-00
Page 91-42
R w W : Aumst 9, 1984
PIPER AIRCRAFT
PA-32-301 /SOIT
MAINTENANCE MANUAL
Figure 9 1-37.Hourmeter (PA-32-301)
Figure 91-38.Hourmeter (PA-32-301
T)
Figure 91-39.Turn and Bank (PA-32-301/301T)
Figure 914. Turn and Bank (PA-32-301
/301T)
91-07-00
P18t 91-43
Rwbd: Au#ust 9, 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
EL929
38607-
hz
..
maw
Y
.'\O-O
20
\\
1
-
\
b
P2A
\\
.
'
SA
nn*
r BANK
&
IFsc3.j1
f
\
\
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\
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-
CZL
-
t
T O N a V LlGClTS
W T
@LI
t
CZE
CY
STANDARD
I~STALLATION
188
PA- - I 0 1
ALTLI(IATL
lLlOmDl
INSTALLATIO*
T8B
m-s
-SOIT
YVC(lNATC
(rl.IILO
I N B T A L U T I O N lOC1 I
Figure 91-41. Turn and Bank (PA-32-301, S/Ws: 32-8106088 and up;
PA-32-30 1T, S/WS: 32-81 2403 1 md .up)
THIS SPACE INTENTIONALLY LEFT BLANK
TO I N S T I I U M N T
LI GUTS
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
ANTI-COLLIION
W t T I D a S 8
ILUX*r(XIDNALl
FOR PA-32-SO11S/Nns:
L
,
--32-m24001
-- - AND UP.
,
,
,
,
I
-----,,,-A
f
4
nlRUlNAL 7
1
SEE WOTE
I
R.WING
STaOeE
-Figure 9 1-42. Anti-Collision Lights (PA-32-30 1 ,
SIN'S: 32-8006001 to 32-8006076; PA-32-30 IT,
S / N's: 32-802400 1 to 32-8024035)
EL915
38607
38634V
-
Figure 91-43. Anti-Collision Lights
(PA-32-30 1, SIN'S: 32-8006077 and up;
PA-32-30 1 T, S / N's: 32-8024036 and up)
LANDING LIGHT
THIS SPACE INTENTIONALLY
LEFT BLANK
NOTE:
FOR Pk32-301. S/N'r:
32-8106099 AND UP.
#
Figure 91-44. Landing Light (PA-32-30] 1301 T)
-
PIPER AIRCRAFT
PA-3%301/301T
MAINTENANCE MANUAL
'
COUPT. LT.
1
-
-
NOTE:
FOR S I N ' S :32-0008077 TO 32-8106087
LT ISWITCW
Figure 91-46. Cabin Lights, Optional
(PA-32-301, SIN'S:32-8106088 and up)
Figure 9 1-45. Cabin Lights, Optional
(PA-32-30 1, Early Models)
TO urncri RELAY
(ALTtRW.
STARTERl
LT. / SWITCH
Figure 91-47. Cabin Lights, Optional
(PA-32-301T, Early Models)
I
LTIullTCH
Figure 9148. Ca6in Lights, Optional
( P A ~ ~ o SIN'S:
~ T . 32-812403 1 and up)
-
91-07-00
Page 91-46
Revised: August 9, 1984
I
PIPER AIRCRAFT
PA-32-=/301T
MAINTENANCE MANUAL
Figure 9149. Instrument, Navigation and Radio Lights rad Dimmer Control Assembly (PA-32-301,6/N*s:
32-8006001 to 32-8006076, PA-32-301T. S ~ W S32-8024001
:
to 32-8024035)
PIPER AIRCRAFT
PA-32-301 / a 1 T r
MAINTENANCE MANUAL
U A COWllEClED TO STARTER AND
ACCESS. CIRCUTBREAXEIION S/N'a.
Figure 91-50. Instrument, Navigation and Radio Lights and Dimmer Control Assembly
(PA-32-301, S/ WS: 32-8006077 to 32-8106087)
PIPER AIRCRAFT
PA-32301/301 T
MAINTENANCE MANUAL
&UTOCI LOT
. TO DKilTAL CLOCK
. TO TURN AND BANK
Figure 91-51. Instruments, Navigation'md Radio Iighu and Dimmer Control Assembly
(PA-32-301, S / N's: 32-8 106088 to 32-8 106098)
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
2. FOR S/N'r: 32-81m099AND
3 TO DIGITAL CLOCK (OPT.)
4. TO TURN AND BANK
Figure 91-52. lnsthment, Navigation and Radio Lights and Dimmer Control Assembly.
(PA-32-301, S/N's: 32-8 106099, 32-8106100 and up)
91-07-00
P ~ g 91-50
t
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301Ij01T
MAINTENANCE MANUAL
DIGITAL CLOCl
Figure 91-53. Instrument, Navigation and Radio Liatn and Dimmer Control Aucmbly
(PA-32-30 1 T,S/ N's: 32-8024036 to 32-8 124030)
PIPER AIRCRAFT
PA-32-301/30 1T
MAINTENANCE MANUAL
OIYOCW LWGL
I
NOTES:
1. TO ELT WSTAUATlON (OPT.)
2 tO WARTER AND ACCESS. CIRCUIT BREAKER
3. TO DIGITAL CLOCK
4.TO 7URN AND DANK
6.SEE FIOURE 91-47K)R PA-S-301T. S/N'S:
li-812AND UP
OVERHEAD
-
--
Figure 91-54. Instrument, Navigation and Radio Lights and Dimmer Control Assembly
(PA-32-301T. SIN'S: 32-812403 1 to 32-8124046)
91-07-00
Page 91-52
Revised: August 9, 1984
PIPER AIRCRAFT
PA-3&301/301T
MAINTENANCE MANUAL
OXlOtN OIUGL
NOTES:
1. TO EL1 #JSTAUA'TK)N (OPT.)
2. TO SIARTER AND ACCESS. aRcurr BREAKER
3. TO DKilTAL CLOCK
4.
L
--
TO TURN AND BANK
--
Figure 9 1-55. instrument, Navigation and Radio Lights and Dimmer Control Assembly
(PA-32-30 1 T. S / Ws: 32-8224001 and up)
I
PIPER AIRCRAFT
PA-32-301/MlT
MAINTENANCE MANUAL
L
E l 020
38607
30634
CUYmtn
.
a mL U I a
lo-
I
1
:
CAaatmasn
:
n t ~ o ~ m La I a a v a
-:
Figure 9 1-56. Passenger Reading Lights (PA-32-30 1 / 301 T, Early Models)
.
EL 909
38607
38634
CASSLNGCR
RCADING LIGMTS
NOTE.
FOR CA.32-301. SIN'$: 32-81OWW AND Uk PA-32.3011.
S/N'r: 32-8124031 AND UP.
F
n
(dl
d
FWD
-
LLFT
PWO RIGMT
I \
c2-
AFT
LEFT
---
41
A F T RIGMT
Figure 9 1-57. Passenger Reading kghu (PA-32-301 1301T. Later Models)
PIPER AIRCRAFT
PA-32-301 1301T
MAINTENANCE MANUAL
THIS SPACE INTENTIONALLY
LEFT BLANK
-
FOR M-32-301, S/N'r: 328100008 AND UP; PA-31-301T.
Figure 91-58. Warning (PA-32-301 /301T)
THIS SPACE INTENTIONALLY LEFT BLANK
91-07-00
Page 91-55
Revised: A u ~ s 9,
t 1984
I
PIPER AIRCRAm
PA-32-301/BIT
MAINTENANCE MANUAL
GRIDS 3E1S THRU 3EU
INTENTIONALLY LEFT BLANK
CHAPTER
SPECIAL PURPOSE
EQUIPMENT
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE M A N U A L
-
CHAPTER 95 SPECIAL PURPOSE EQUIPMENT
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTIOS
SUBJECT
95-00-00
GRID
SUBJECT
GENERAL
RO.
3 F3
EFFECTIVITY
A 8-82
SPECIAL TOOLS
Tire Balancer Fabrication lnst ructions
Orifice Replacement Tool
Fabricated Tool for Baggage Door Lock
Retainer Ring Tool
Control Surface Rigging Tools
Fabricated Aileron Bellcrank Rigging Tool
Fabricated Rudder Rigging Tool
Fabricated Aileron and Flap Rigging Tool
Fabricated Stabilator Rigging Tool
Control Surface Balancing Tool
-
95 Cont./Effec.
Page 1
Revised: August 9, 1984
-
PIPER AIRCRAFT
PA-32-301 /3@1T
MAINTENANCE MANUAL
I
1
Figure 95- 1. Tire Balancer Fixture
GENERAL.
SPECIAL TOOLS.
I
This Chapter contains illustrations of the various fabricated and purchased special tools which ma!. be
required when performing various maintenance tasks on the airplane.
TIRE BALANCER (FABRICATIONS INSTRUCTIONS.)
1
1. Chamfer top edges of -3 sides. leaving 1 !16 inch flat on top inboard edge. Rivet -2 tee's to -3 sides
using A S 470-AD5 rivets 2" spacing. Use AN 426-AD5 rivets 2" center t o center to secure -2 tee's to - I base. I f
tee extrusion is unavailable. heavy angle extrusion could be used. -3 sides must be vertical.
2. The 4 axle must slide through the -8 pipe. The -5 nuts were made by reaming the existing threads in
the AN 365-624 nuts with an R drill. then tapping with a 1/8-27 pipe tap.
3. The -6 spacers were made from I I2 inch aluminum tubing. The two lengths of spacers are suitable for
balancing most any aircraft wheel.
4. The -7 bushings may be made from one inch phenolic or aluminum using a I- I 12 inch hole saw to cut
out the smaller bushing and a 1-3!4 hole saw to cut out the larger. By inserting a 114 inch long threaded bolt
through the pilot hole and securing with a washer and nut. a drill pressand file may be used to make the off-set
on the bushing. The turneddown p a n should just slide inside the bearing race. Ream the pilot hole to slide
over the -8 pipe threads.
5. The -8 pipe was made from a piece of 1 i 8 inch black pipeand threaded witha 1 :8-27 pipe die. Thread
3 inches in from each end of the pipe.
95-10-01
Page 95-01
Rwistd: August 9, 1984
PIPER AIRCRAFT
PA-32-301 /301 T
MAINTENANCE MANUAL
MATERIAL: STEEL
9 5 10-02
Pigt 95-02
Revised: August 9, 1985
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
Figure 95-3.Fabricated Tool for Baggage Door Lock
Figure 95-4. Retainer Ring Tool
95- 10-04
Page 95-03
Revised: August 9. 1984
PIPER AIRCRAFT
PA-32-301 /301T
MAINTENANCE MANUAL
I
CONTROL SURFACE RIGGING TOOLS.
A114
MATERIAL:
,126 X 3.90 X 1.0 ALUM. PLATE
OR
.126 X 3.86 X 1.0 ALUM. PLATE
Figure 95-5. Fabricated Aileron Bellcrank Rigging Tool
4 FWD
MATERIAL
STEEL OR HARD ALUMINUM
125X20OX6187PLATE
-
- -
-
p
Figure 95-6. Fabricated Rudder Rigging Tool
95-1 0-07
Page 95-04
Revised: Auuust 9. 1981
PIPER AIRCRAFT
PA-32301 /301T
MAINTENANCE MANUAL
1
All@
MATERIAL:
.750 x 31.50 x 4.00 ALUM. BAR OR
.750 x 31 .SO x .750 SQ. ALUM. BARSTOCK (MIN.)
NOTES:
1. DRILL AND TAP TO 10-32 NF. AN-3 BOLT,
JAM NUT AND INTERNAL STAR WASHER
MAY BE USED FOR SPACER OR AN-3 BOLT
WITH HEAD FILED TO REQUIRED LENGTH
2. SPAR STOCK MAY BE USED IN PLACE OF
ALUM. BAR STOCK.
SEE NOTE I
SEE NOTE 2
b
I
Figure 95-7. Fabricated Aileron and Flap Rigging Tool
95-1 0-08
P a p 95-05
Revised: August 9. 1984
PIPER AIRCRAFT'
PA-32-301 /301 T
MAINTENANCE MANUAL
m
112
/I
MATERIAL
1OX2319X3LUALUMBAR
SLRCACE PARALLEL TO MSE LINE
I
S T U I LATOA -OUR
.003
1.12
1%
a
++
4+2403
1.dO
1.39
-.a SET UCU
1.29
.82
1 10
- *
.- ....
2.19
::
-- -
--,
- --D U E LINE
T
1.63
2000
16.03
0
16.W
'1
LEADING EDGE
I
.
Figure 95-8. Fabricated Stabilator Rigging Tool
95-10-09
Page 95-06
Revised: August 9,1984
PIPER AIRCRAFT
PA-32-301I301T
MAINTENANCE MANUAL
4
3 LB MOVABLE WEIGHT WITH
MARKED CENTERLINE
CYI
NUTS AND OR
WASHERS ADDED
AS REOUIRED
SURFACE CHORD LlNE
BEAM BALANCING
BOLT (USED FOR
BALANCING THE
TOOL ITSELF ONCE
THE TRAILING
EDGE SUPPORT
HAS BEEN SET1
5 FT EXTRUDED CHANNEL
HINGE CLNTERLINE
MARK GRADUATIONS IN INCHES
PLACED DIRECTLY OVER
HINGE LlNE OF CONTROL SURFACE
HORIZONTALLY
ADJUSTABLE FOR
SElllNG TOOL TO
WIDTH OF CONTROL
SURFACE
BUBBLELEVEL
VERTICALLY AND W R I Z W T A L L Y
ADJUGTABLE TRAILING LOGE m R
T
VERTICALLY ADJUSTABLE
FOR SEnlNG BEAM
PARALLEL TO CHORD
LlNE OF CONTROL SURFACE
Figure 95-9. Control Surface Balancing Tool
95-10-10
Revised: August 9, 1984
PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
GRIDS 3F10 THRU 3L24
INTENTIONALLY LEFT BLANK